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Busbar Systems 160...

800 A

KO-II

E-LINE KX
Compact Busbar Distribution System
630...6300 A

E-LINE KB
Compact Busbar Distribution System
800...6300 A

E-LINE KO
Plug-in Busbar Distribution System
160...800A

E-LINE MK
Small Power Plug-in Busbar Distribution System
100-160-225A

E-LINE KAP
Plug-in Busbar Distribution System
40-63A

E-LINE DL
Multi-Conductor Lighting Busbar System
25-32-40A

E-LINE KAM
Lighting Busbar System
25-32-40A

E-LINE TB
Multi Conductor Trolley Busbar System
35...250A

E-LINE DK
Underfloor Ducting Systems

E-LINE DKY
Raised Floor Energy Distribution Systems
25...63A

E-LINE UK
Cable
Tray Systems

Y A N D EN V

IT
AL

ME 04

QU

ISO
9001
14001

MENT SYSTE
M

IEC 60439-2

MENTAL MAN
ON

E
AG

IR

EAE Elektrik A..


Akcaburgaz Mahallesi,
119. Sokak, No:10 34510
Esenyurt-Istanbul-TURKEY
Tel: +90 (212) 866 20 00
Fax: +90 (212) 886 24 20
www.eae.com.tr

Catalogue 13-Eng. / 05 1000 Pcs 21/10/2013


ATA LTD. / F.A./ www.atamatbaa.net
EAE has full right to make any revisions or changes on this catalogue without any prior notice.

CONTENTS
E L E K T R K

E-LINE KO-II
Introduction

2-3

Design

Order Code System

Technical Characteristics

Standard Components

Elbows

8-11

Standard Components

12-13

Feeder Boxes

14-15

Selection Of Feeder Boxes

16

Panel Connections

17

Tap-off Boxes

18-20

Fixing Elements

21-22

Vertical and Horizontal Busbar Applications

23-24

Expansion Modules Application

25

Fire Barrier

26

Determination of Special Length

26

Installation of End Closer

27

Mounting Instructions for Joints

27

EC Declaration Of Conformity

28

Certificates

29

Product Overview

30

Project Design Form

31-32

ELINEKOIntroduction
E-Line KO- Busbar System distributes electrical power,
both vertically and horizontally at premises where there
is a need for electrical power 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 a reliable power supply such as business centres,
hotels, hospitals, warehouses and
all high rise buildings.

Fast, Flexible Engineering


The large number tap-off points makes it possible to
engineer the power supply systems at an early stage,
even before the final distribution of loads is known.

Modern Appearance
Other than its functional advantages E-Line KObusbar system also creates a modern appearance in
buildings where it is used.
Lower Life Cycle Cost
Busbar components can be added, removed or
relocated after the initial installation, saving time
and money.
Tap-off Points
Power can only be supplied by E-Line KO- tap-off
boxes. Where necessary the unused tap-off points can
be restricted by sealing. Dust covers protect the system
from any accidental contact and also prevents the ingress
of pollutants from the environment.

Fast and Easy Mounting


Power is easily supplied to machines by E-Line KO- .
The installation of the system does not require any
expertise. Supports and accessories are available for
mounting the system either from the ceiling or the wall.

55

Nm

Safe Power Distribution and Transportation


E-Line Busbar Systems increase personnel safety
by their special features.
Lower Total Installed Cost
Total Busbar material and installation costs are often
equal to or less than cable and conduit .
Flexible Power Supply
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
- Copper and Aluminium conductors are tin plated
along their length.

Safe Power Take Off


The earth of the tap-off box makes contact with
the busbar first and ensures the safety, of the
box andthe system thats been fed.

- Cross-section of neutral conductor is the same as


the phase conductors.
- Upon request the KO- range can also be
manufactured with 5 conductors.

ELINEKODesign
Diversity Factor (a)

While designing an electrical distribution


system with E-Line KO- a few approximate
details will be necessary.
Location, number, type and approximate
ratings of loads,
Transformer rates and short-circuit capacities,
Utilization factor = a
System co-ordination with other distribution
systems (heat, water, etc.)
Determining the route of E-Line KO- on layouts,
Deciding on suitable supports,
If necessary, co-ordination of E-Line KB
and E-Line MK-KAP with E-Line KO- runs.

The diversity factor(a) depends on the type and number of loads.


It is usually around 0.7 or lower. The diversity factor of a line
supplying electric motors and lighting systems is usually 0.6 It is
as low as 0.5 in welding shops of car factories,
(a) can be 1 in lines where only one big load is supplied.
Applications
As each buildings structure is different from another for
vertical and horizontal applications special projects have to be
designed.

End Of Line

Rated Current
a= ......

The current is calculated using the following


equation.
Special Length Busbar

h= ......

e r
Fir rrie
Ba

h= ......

P13
8.Floor

-in

Po
in

Pl

ug

-n

Ta
p

ff B

Pl

ox

ug

Po
in

-in

Tap-off Point

1.

-o

l
ca
rti rt
Ve ppo
Su

P11
6.Floor

a= ......

P10
5.Floor

a= ......

4.Floor

P9
P8

3.Floor

P7
P6

a= ......

a= ......

P5
2.Floor

a= ......
h= ......

)
ing m
eil s (m
) Cnes
a
( ick
Th

h= ......

ug

P12
7.Floor

a= ......

h= ......

Pl

h= ......

a= ......

3.

Standard Length Busbar

P14
9.Floor

a= ......

h= ......

Busbar Current rating is chosen as equal to or


higher then the calculated IB current.
After the voltage drop calculation if the chosen
current rating is too low, a higher rating
should be selected.

10.Floor

a= ......

h= ......

IB = Operating Current (A)


P = Installed Load
(W)
a = Utilization Factor
U = Supply Voltage

l
ca
rti rt
Ve ppo
u
S

h= ......

3.U.cos j

(H) Height of storey measured from ceiling (mm)

P.a

Expansion Unit

IB =

Vertical Distribution

h= ......

a= ......

Pre-Project Design and cost Analysis

a= ......

P2

h= ......

1. Basement

P1
2. Basement

h= ......

a= ......

Location and dimensions of the shaft


where busbar will be installed,
(h=)
Number, height and ceiling thickness of each storey, (a=)
Connected load for each storey,
(p=)
Supply type to the vertical line (Busbar or Cable).

P3
Ground Floor

h= ......

The details on this page briefly explain the necessary


information required for designing a vertical application project.

a= ......

The details below should be sent to our Project and Design


Department for Pre-Project design and cost analysis.

P4
1.Floor

3. Basement

Figure 1

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Order Code System

KO

06

5 -

Busbar Type

Aluminium
Copper

Components

Aluminium

Conductor Type

A
C

Busbar
Rated Current

Copper

- B - DDT

01

6x20

250

02

6x25

315

03

6x30

400

04

6x50

500

05

6x62,5

600

06

6x75

250

02

6x20

315

03

6x25

400

04

6x30

600

06

6x50

800

08

6x75

IP 55

Busbar Code

Protection Degree

Right Elbow
Left Elbow
Downwards Elbow
Upwards Elbow

R
L
A
Y

Upwards Vertical Offset


Downwards Vertical Offset
Right Horizontal Offset
Left Horizontal Offset

UV
DV
RH
LH

T Component
Cross
Reductions

T
D
RD

End Closer
Horizontal Expansion
Vertical Expansion
Flexible

S
YDT
DDT
F

Feeder Box 1
Feeder Box 2
Central Feeder Box 1
Central Feeder Box 2

B1
B2
BO1
BO2

Panel Connections
Panel Connections

P10
P11

Paint

Conductor Configuration
Number of
Conductors

STD
X
FTD
FX

Right Upwards Combined KRU


KLU
Left Upwards Combined
Right Downwards CombinedKRD
Left Downwards Combined KLD
Upwards Right Combined KUR
KUL
Upwards Left Combined
Downwards Right CombinedKDR
Downwards Left Combined KDL

Busbar
Code

160

Plug-in Standard Length


Plug-in Special Length
Feeder Standard Length
Feeder Special Length

UNPAINTED
PAINTED

Configuration
Code
L1

4 wire

5 wire

4 wire

5 wire (CPE)

4 wire (CPE)

L2

L3

PE

PE

CPE

PE
CPE (Housing)

ELINEKOTechnical Characteristics
Aluminium Conductor (KOA)
In

Rated Current

Busbar Code

Copper Conductor (KOC)

160

250

315

400

500

600

250

315

400

600

800

01

02

03

04

05

06

02

03

04

06

08

Standards

IEC 60439-2

Rated Insulation Voltage

Ui

1000

Rated Operational Voltage

Ue

1000

Rated Frequency

Hz

50 / 60

Measures For Protection


Against Electric Shock

Basic protection (HD 60364-4-41,clause A1)

Pollution Degree

55

Protection Degree

IP

Housing Material

Pregalvanized sheet metal or epoxy polyester painted pregalvanized sheet metal RAL 7038

Rated Short-time Withstand


Current (1 sec)
Rated Peak Withstand
Current
Rated Short-time
withstand Current (N)
Rated Peak Withstand
Current (N)
Rated Short-time
Withstand Current (PE)
Rated Peak Withstand
Current (PE)

Icw

kA rms

10

15

15

30

30

35

18

18

25

35

35

Ipk

kA

17

30

30

63,5

63,5

73,5

36

36

52,5

73,5

73,5

Icw

kA

18

18

21

10,8

10,8

15

21

21

Ipk

kA

10,2

15,3

15,3

36

36

44,1

21,6

21,6

30

44,1

44,1

Icw

kA

18

18

21

10,8

10,8

15

21

21

Ipk

kA

10,2

15,3

15,3

36

36

44,1

21,6

21,6

30

44,1

44,1

The Mean Ohmic Resistance


at 20C and at In

R 20

mW/m

0,242

0,193

0,161

0,097

0,077

0,064

0,150

0,120

0,100

0,060

0,040

Mean Ohmic Resistance at the Steady


State Operation Temp. (q1) and at In

R1

mW/m

0,286

0,246

0,204

0,125

0,109

0,094

0,180

0,164

0,144

0,078

0,068

Mean Ohmic Reactance at the Steady


State Operation Temp. (q1) and at In

X1

mW/m

0,205

0,183

0,165

0,118

0,103

0,088

0,173

0,154

0,144

0,117

0,083

Mean Ohmic Impedance at the Steady


State Operation Temp. (q1) and at In

Z1

mW/m

0,333

0,319

0,270

0,182

0,157

0,135

0,254

0,235

0,207

0,144

0,110

3IR1

W/m

23,58

48,75

64,05

62,08

84,41

104,68

35,36

50,33

70,92

86,19

133,56

L1, L2, L3, N

mm

120

150

180

300

375

450

120

150

180

300

450

PE (for 5 conductors)

mm

120

150

180

300

375

450

120

150

180

300

450

PHASE CONDUCTORS

Power loss at rated current


SECTIONS

PE (for 4 conductors)

mm

60

75

90

150

187,5

225

60

75

90

150

225

Housing Cross Section


(Steel Sheet)

mm

583

593

603

643

668

693

583

593

603

643

693

mmxmm

6x20

6x25

6x30

6x50

6x62,5

6x75

6x20

6x25

6x30

6x50

6x75

Weight - 4 Conductors

kg/m

7,0

7,5

8,0

10,0

11,0

12,0

10,0

11,0

12,5

16,0

18,0

Weight - 5 Conductors

kg/m

7,3

8,0

8,7

11,0

12,0

13,0

11,0

12,5

14,0

19,0

21,0

mW/m

0,965

0,901

0,847

0,614

0,572

0,516

0,954

0,915

0,793

0,597

0,453

Z 0-ph-PE mW/m

1,100

1,030

0,961

0,825

0,709

0,687

1,042

0,959

0,911

0,779

0,691

Conductor Size

Fault condition (1) ;


Zero empedance at 20C
Zero empedance at 20C
(Housing)

Z 0-ph-N

(1)

Measurements and calculations of fault-loop circuit is done according to EN 60439-2 appendix N2a.

Voltage Drop Calculation


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

DU= 3.L.I.(R1 .Cosj+X1.Sinj) 10

= Voltage Drop (V)


= Load Distribution Constant
L
= Line Length (m)
I
= Line Current (A)
R1
= Resistance (mW/m)
X1 = Inductive Reactance (mW/m)
Cosj= Load Factor

DU
S

= Supply Point

-3

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Standard Components

KO

625

375

500

500

500

500

500

500

500

500

375

625

3000

Sample Order:
250 A, Aluminium, Plug-in,
IP 55, 4 Conductors

KOA 0254- -STD

Plug-in
Standard Length

- STD
00

30

L1
L2
L3
N
PE

Electrical Power up to 400A can be supplied


from the busbar by Tap-off boxes.
E-Line KO- Busbar is manufactured in 3m
lengths as standard, special lengths can be
manufactured on request.

Sample Order:
400 A, Copper, Plug-in,
IP 55, 850 mm. 5 Conductors

KOC 0455-

-85

Plug-in
Special Straight Length

X
X

Minimum special length that can


be manufactured is 350 mm.

L1
L2
L3
N
PE

X Special
Straight Length
(mm)

Sample Order:
315 A, Aluminium, Feeder,
IP 55, 5 Conductors

KOA 0355-

-FTD

Feeder
Standard Length

- FTD
00

30

L1
L2
L3
N
PE

L1
L2
180

L3
N
PE

Current Aluminium Copper


(A)
(A)
(A)
160
250
315
400
500
600
800

mm
70
75
80
100
112
125
-

mm
70
75
80
100
125

Busbar cross-section dimensions


Please call us for non-standard components.

Sample Order:
160 A, Aluminium, Feeder,
IP 55, 600 mm, 4 Conductors

KOA 0154-

-60

Feeder
Special Straight Length

FX
X

X Special
Straight Length
(mm)

L1
L2
L3
N
PE

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Elbows

KO

Right Elbow
A

Sample Order:
250 A, Aluminium, IP 55, 4 Conductors

KOA 0254 -

-R

L1
L2
L3
N
PE

Left Elbow

Sample Order:
600 A, Copper, IP 55, 5 Conductors

-L

L1
L2
L3
N
PE

KOC 0655 -

Downwards Elbow

Aluminium

145
147
150
160
166
172

200
200
200
200
200
200

290
290
290
290
290
290

250
315
400
600
800

180
185
190
210
235

145
147
150
160
172

200
200
200
200
200

290
290
290
290
290

L1
L2
L3
N
PE

Upwards Elbow

Sample Order:
600 A, Copper, IP 55, 5 Conductors

KOC 0655 -

-Y

L1
L2
L3
N
PE

C
D

Please call us for non-standard components.

180
185
190
210
222
235

Current

-A

160
250
315
400
500
600

Copper

KOA 0454 -

Sample Order:
400 A, Aluminium, IP 55, 4 Conductors

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Elbows

KO

X= min. 200 mm.


Sample Order:
250 A, Aluminium, IP 55,
4 Conductors

KOA 0254 -

- UV

Upwards Vertical
Offset

UV

L1
L2
L3
N
PE

Downwards
Vertical Offset
X= min. 200 mm.
Sample Order:
400 A, Copper, IP 55,
5 Conductors

KOC 0455 -

- DV

X
DV

L1
L2
L3
N
PE

Y= min. 150 mm.

Right Horizontal
Offset

KOA 0355 -

- RH

A
B
B

Sample Order:
315 A, Aluminium, IP 55,
5 Conductors

RH
L1
L2
L3
N
PE

Aluminium

145
147
150
160
166
172

200
200
200
200
200
200

290
290
290
290
290
290

250
315
400
600
800

180
185
190
210
235

145
147
150
160
172

200
200
200
200
200

290
290
290
290
290

Y= min. 150 mm.

Left Horizontal
Offset

Sample Order:
160 A, Aluminium, IP 55,
4 Conductors

- LH

LH
L1
L2
L3
N
PE

KOA 0154 -

180
185
190
210
222
235

Copper

160
250
315
400
500
600

Current

Please call us for non-standard components.

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Elbows

Y= min. 200 mm.


Sample Order:
250 A, Aluminium, IP 55,
4 Conductors

- KRU

Right Upwards
Combined Offset

KRU

KOA 0254 -

KO

L1
L2
L3
N
PE

Y= min. 200 mm.


Sample Order:
400 A, Copper, IP 55,
5 Conductors

KOC 0455 -

- KLU

Left Upwards
Combined Offset

KLU

L1
L2
L3
N
PE

KOA 0355 -

- KRD

A
B

X= min. 200 mm.


Sample Order:
315 A, Aluminium, IP 55,
5 Conductors

Right Downwards
Combined Offset

KRD

Aluminium

200
200
200
200
200
200

290
290
290
290
290
290

250
315
400
600
800

180
185
190
210
235

145
147
150
160
172

200
200
200
200
200

290
290
290
290
290

Please call us for non-standard components.

10

X= min. 200 mm.


Sample Order:
160 A, Aluminium, IP 55,
4 Conductors

KOA 0154 -

- KLD

Left Downwards
Combined Offset

KLD

L1
L2
L3
N
PE

145
147
150
160
166
172

180
185
190
210
222
235

Current

160
250
315
400
500
600

Copper

L1
L2
L3
N
PE

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Elbows

KO

Y= min. 200 mm.


Sample Order:
250 A, Aluminium, IP 55,
4 Conductors

KOA 0254 -

- KUR

Upwards Right
Combined Offset

KUR

L1
L2
L3
N
PE

Y= min. 200 mm.


Sample Order:
400 A, Copper, IP 55,
5 Conductors

KOC 0455 -

- KUL

Upwards Left
Combined Offset

KUL

L1
L2
L3
N
PE

D C

X= min. 200 mm.


Sample Order:
315 A, Aluminium, IP 55,
5 Conductors

KOA 0355 -

- KDR

Downwards Right
Combined Offset

KDR

L1
L2
L3
N
PE

160
250
315
400
500
600

180
185
190
210
222
235

145
147
150
160
166
172

200
200
200
200
200
200

290
290
290
290
290
290

250
315
400
600
800

180
185
190
210
235

145
147
150
160
172

200
200
200
200
200

290
290
290
290
290

Copper

Aluminium

Current

X= min. 200 mm.


Sample Order:
160 A, Aluminium, IP 55,
4 Conductors

KOA 0154 -

- KDL

Downwards Left
Combined Offset

KDL

L1
L2
L3
N
PE

B
A

Please call us for non-standard components.

11

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Standard Components

KO

Reduction
Is used to change the busbar
cross section.

Reduction
L1
L2
L3
N
PE

Sample Order:
400-250 A, Aluminium,
IP 55,5 Conductors

NOTE:
The selection of the reduction unit
and the lower side protection is the
responsibility of the customer.

KOA 0455 -

- RD2

RD

Reducers Table

64

KOA - Al
Conductor

KOC - Cu
Conductor

Rated Reduced Busbar Current


Current 160 250 315 400 500
250
315
400
500
600

Rated Reduced Busbar Current


Current 250 315 400 600
315
400
600
800

T Component

Sample Order:
250 A, Aluminium, IP 55,
4 Conductors

KOA 0254 -

-T

T
L1
L2
L3
N
PE

160
250
315
400
500
600

290
295
300
320
332
345

145
147
150
160
166
172

250
315
400
600
800

290
295
300
320
345

145
147
150
160
172

Copper

Aluminium

Current

Please call us for non-standard components.

12

Cross

A
A

Sample Order:
600 A, Aluminium, IP 55,
4 Conductors

KOA 0654 -

-D

D
L1
L2
L3
N
PE

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Standard Components

KO

End Closer

End Closer
Is used to close the end of busbar run.

Sample Order:
250 A, Copper, IP 55, 5 Conductors

KOC 0255 -

-S

10

Horizontal Expansion
Horizontal Expansion
For long horizontal runs and for
crossing the building expansions.
(See page no.25 for application)

Sample Order:
250 A, Aluminium, IP 55, 4 Conductors

KOA 0254 -

- YDT

L1
L2
L3
N
PE

YDT

00

10

Vertical Expansion
Vertical Expansion
For vertical applications in
multi- storey buildings.
(See page no.25 for application)

L1
L2
L3
N
PE

Sample Order:
250 A, Copper, IP 55, 5 Conductors

KOC 0255 -

- DDT

70

DDT

Flexibles
Are used for panel-busbar
connections.

Flexibles

Sample Order:
400 A, Aluminium, 4 Conductors 550 mm.

- F55

(mm)

Z Y

KOA 0454 -

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


Please call us for non-standard components.

13

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Feeder Boxes

KO

L1
L2
L3
N
PE

Feeder Box 1
Sample Order:
250 A, Copper, IP 55,
5 Conductors

KOC 0255 -

- B1

B1

Feeder Box 2
Sample Order:
250 A, Aluminium IP 55,
4 Conductors

KOA 0254 -

210

200

-B2

B2

D
X
B

L1
L2
L3
N
PE

X
Y

160

550

350

350

180

85

55

250

550

350

350

180

85

52,5

315

550

350

350

180

85

50

400

550

350

350

180

85

40

500

550

350

350

240

85

65

600

550

350

350

240

85

57,5

250

550

350

350

180

85

55

315

550

350

350

180

85

52,5

400

550

350

350

180

85

50

600

550

350

350

180

85

40

800

550

350

350

240

85

57,5

Aluminium

Current

210

200

X
B

Copper

X
Feeder Box sample equipped with MCCB

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

14

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Feeder Boxes
(Central Feeder Box BO)
KO

Central
Feeder Box BO 1
Sample Order:
600 A, Aluminium, IP 55,
4 Conductors

BO1

- BO1

600

KOA 0654 -

36

21
L1
L2
L3
N
PE

60

23

21

Central
Feeder Box BO 2
Sample Order:
600 A, Aluminium IP 55,
4 Conductors

BO2

- BO2

36

600

KOA 0654 -

21
L1
L2
L3
N
PE

60

23

21

145

107,5

PE
L3

L2

L1
365

270

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

15

ELINEKOSelection of Feeder Boxes

B2

B2
B1

B1

Standard Length Busbar

Ceiling

150 mm.

Application of
Tap-off Boxes for
Horizontal Lines

L1
L2
L3
N
PE

In horizontal installation the neutral


conductor is situated as shown above.

2.

Plu

g-

150 mm.

al
rtic rt
Ve ppo
Su

Vertical Expansion

e r
Fir rrie
Ba

Special Length Busbar

B2

in

Po
in

150 mm.

1.
Ceiling

Plu

g-

in

Po
in

L1
L2
L3
N
PE

Wall

FRONT
Application of Tap-off Boxes
for Vertical Lines

In vertical installation the neutral


conductor should be on the right side.
It is important for tap-off box connections.

16

B1

ELINEKO-

BUSBAR TYPE
CONDUCTOR TYPE
BUSBAR CODE
PROTECTION DEGREE
CONDUCTOR CONFIGURATION
UNPAINTED / PAINTED
COMPONENT

Panel Connections

KO
Figure 1

Figure 2
Busbar Feeder

410

Sample Order:
600 A, Aluminium, IP 55, 5 Conductor

KOA 0655 -

- P10

P10
200

Busbar Feeder

x
y

z
A

Figure 3

Figure 4

PE

L3
L2
L1

Panel Feeder

410

z
t
A

Sample Order:
600 A, Aluminium, IP 55, 5 Conductor

x
y

KOA 0655 -

- P11

200

x
y

P11
Panel Feeder

Figure

160
250
315
400
500
600

20
25
30
50
62,5
75

40
40
40
40
40
40

20
20
20
20
20
20

9
11
11
13,5
13,5
13,5

40

1
2
2
3
3
4

250
315
400
600
800

20
25
30
50
75

40
40
40
40
40

20
20
20
20
20

9
11
11
13,5
13,5

40

1
2
2
3
4

E-Line KOBusbar

180

145

140
460

145

15

Opening on the panel board

50

Panel
Connection
Plate

1503

150

100
100
15

L2

Panel Connection
Plate

Note: 230x460mm flange plate


dimensions are standard for
all busbar types.

PE

L1

410

15

400

N
L3

210

260

Aluminium

Copper

Current

65

70

70

70

Please call us for non-standard components.

17

ELINEKO-

BUSBAR TYPE
BOX TYPE

Tap-Off Boxes
with Fused Switches (SYK)

BOX RATING
PROTECTION
DEGREE

160 A - 16
250 A - 25
400 A - 40

IP 55 5

KO P

FUSED
SWITCHES TYPE

S- STANDARD SYK
B- EMPTY

Cable Gland Plates


Inner
Diameter
(mm)

Cable
Gland Type

Order
Code

Sheet
Metal

----

RP0

Sheet
Metal

M32

RP1

25

Sheet
Metal

M40

RP2

32

Sheet
Metal

Special

RP3

63

AL

2xSpecial

RP4

63

AL

4xM25

RP5

18

AL

4xM32

RP6

25

Mat.

tes )
Pla es
d sid
n
a
Gl two
on

B
L1
L2
L3
N

KOP 1651-S

tess)
Plaide
s
d
an e
Gl thre
on

B
L1
L2
L3
N

KOP 2551-S
AL

4xM40

RP7

32

AL

8xM32

RP8

25

Fused Switches (SYK)

tess)
Pla de
d si
n
a e
Gl thre
n
(o

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

L1
L2
L3
N

KOP 4051-S

mm

mm

mm

KOP 160 370


KOP 250 480
KOP 400 625

300 195
380 245
380 255

Cable
Gland

Fuse
Size

RPK1
RP2
RP3

NH 00
NH 1
NH 3

Fused
5W
Switches Order No.

KYA
KYA
SYK

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.
Please call us for non-standard components.

18

49795
49797
95053

50

CURRENT

30

30

ELINEKO-

BUSBAR TYPE
BOX TYPE

Tap-Off Boxes
for MCCBs

BOX RATING
PROTECTION
DEGREE
IP 55 5

KO P

160 A - 16
250 A - 25
400 A - 40

FUSED
SWITCHES TYPE

Cable
Gland Type

Mat.

(o G
n la
n
th d
re P
e la
si te
d s
e
s)

Cable Gland Plates


Order
Inner
Code Diameter
(mm)

----

RP0

Sheet
Metal

M32

RP1

25

Sheet
Metal

M40

RP2

32

Sheet
Metal

Special

RP3

63

AL

2xSpecial

RP4

63

AL

4xM25

RP5

18

AL

4xM32

RP6

25

----

AL

4xM40

RP7

32

AL

8xM32

RP8

25

L1
L2
L3
N

KOP 1651-M1
KOP 1651-B1

B
L1
L2
L3
N

KOP 2551-M1
KOP 2551-B1

Special Cable Gland Plates

Cable
Mat. Gland Type

Order
Inner
Code Diameter

Sheet
Metal

----

RPK0

----

Sheet
Metal

M25

RPK1

18

Sheet
Metal

M32

RPK2

25

Sheet
Metal

M40

RPK3

32

RPK4

63

(o G
n la
n
th d
re P
e la
si te
d s
e
s)

(mm)

Sheet
Metal

(o G
n la
n
th d
re P
e la
si te
d s
e
s)

Sheet
Metal

1xSpecial

KOP 4051-M1
KOP 4051-B1

L1
L2
L3
N

mm

mm

mm

KOP 160 420


KOP 250 500
KOP 400 675

300 220
300 220
300 220

Cable
Gland

5W
Order No.

RPK2
RPK3
RP3

35484
35486
35504

* EAE tap-off boxes can be designed for all


brands of MCCBs.

50

Current

30

30

Please call us for non-standard components.

19

ELINEKO-

BUSBAR TYPE
BOX TYPE

Tap-Off Boxes

BOX RATING
PROTECTION
DEGREE

40 A - 04
80 A - 08

IP 55 5

SWITCH TYPE

KO P

146
192

105

KOP 0451-B1
KOP 0851-B1
Sample Order:
40 A, IP 55, 5 wire, transparent
hinged lid, suitable for MCB,
empty tap off box

230

190

KOP 0451 - B1

20
30

290

135
181

105

330

KOP 0451-B2
KOP 0851-B2
Sample Order:
40 A, IP 55, 5 wire, transparent
fixed lid, suitable for MCB,
empty tap off box

20
30

290
330

Please call us for non-standard components.

20

230

190

KOP 0451 - B2

B1 -Transparent hinged lid / Empty tap off box


B2 -Transparent fixed lid / Empty tap off box
W -Equipped with MCB
3x6 A
3x10 A
3x16 A
3x20 A
3x25 A
3x32 A
3x40 A
3x50 A
3x63 A
3x80 A

ELINEKOFixing Elements
Tray Supports
Description

Code

(mm)

UAS-K4 SUPPORT (1)

200

3005333

UAS-K4 SUPPORT (2)

250

3005332

UAS-K4 SUPPORT (3)

300

3005331

UAS-K4 SUPPORT (4)

350

3005330

UAS-K4 SUPPORT (5)

400

3005329

UAS-K4 SUPPORT (6)

500

3005328

UAS-K4 SUPPORT (7)

600

3005327

UAS-K4 SUPPORT (8)

700

3005326

UAS-K4 SUPPORT (9)

1100

3005325

Threaded
Rod

KO-UT

40

UAS-K4
L Support

Edgewise
application sample

40

KO-UT
Flatwise
application sample

Tray Supports
Description

Code

(mm)

ASU2A-1

135

3008589

ASU2A-2

250

3008587

ASU2A-3

500

3008585

ASU2A-4

1000

3008583

ASU2A-5

2000

3008168

Threaded
Rod

KO-UT

46

ASU2A

31,5

Edgewise
application sample

KO-UT
Flatwise
application sample

Connection Parts
Description

(mm)

Current Aluminium Copper


(A)
(A)
(A)

Code

BRA 11-05 Threaded Rod (M8)

500

5000039

BRA 11-10 Threaded Rod (M8)

1000

5000038

BRA 12-05 Threaded Rod (M10)

500

5000037

BRA 12-10 Threaded Rod (M10)

1000

5000032

BRA 10 Extension Part (M8)

1004313

BRA 13 Extension Part (M10)

1004312

BRA 9 EAE Pull-off Dowel (M8)

5000033

BRA 9 EAE Pull-off Dowel (M10)

5000023

M8 Steel Nut

1000521

M10 Steel Nut

1000522

M8 Washer

1000502

M10 Washer

1000504

Threaded
Rod

160
250
315
400
500
600
800

mm
70
75
80
100
112
125
-

mm
70
75
80
100
125

Busbar cross-section dimensions

Extension
Part
EAE
Pull-off
Dowel

Diameter of the
hole to be drilled
M8.......12
M10.....14

Steel Nut
Washer

21

ELINEKOFixing Elements
Code

160

115

1004275

250

120

1004278

30

10x

315

125

1004274

400

145

1004277

10

KOA - 5 UT Clamp

500

157

1004265

35

KOA - 6 UT Clamp

600

170

1004276

KOC - 2 UT Clamp

250

115

1004275

KOC - 4 UT Clamp

400

125

1004274

KOC - 6 UT Clamp

600

145

1004277

KOC - 8 UT Clamp

800

170

1004276

Code

Description

(mm)

225

KOA - 3 UT Clamp
KOA - 4 UT Clamp

0
x2
0

42

,5

KO-UT
Clamp

KT 200 Tray Support

235

3008567

KT 250 Tray Support

285

3008565

KT 300 Tray Support

335

3008563

KT 400 Tray Support

435

3008561

KT 500 Tray Support

535

3008559

KT 600 Tray Support

635

3008264

TS 200 Tray Support

205

3008551

TS 200 Tray Support

255

3008549

TS 200 Tray Support

305

3008547

TS 200 Tray Support

405

3008545

TS 200 Tray Support

505

3008543

TS 200 Tray Support

605

3005828

TMP 8 Ceiling Support Unit

3008382

Coupling

1004310

TMP 8

14x20

Vertical Support Set Wall Type

3025371

ASU2A

TS
6

7x1

A
16

11x

KT

Coupling

Vertical Support Set


Wall Type

90

30

Description

Code

Vertical Support Set (Z) Type

3025376

22

Description

(mm)

Code

Vertical Support Set (VS)-40

40

3025379

Vertical Support Set (VS)-60

60

3025378

Vertical Support Set


(Z) Type

90
5

5x3

10,

10
12x20

235

Code

15x35

7,5

1
13
91

Description

155
125
70

75
105

KOA - 1 UT Clamp
KOA - 2 UT Clamp

135

(mm)

25

Current

12

Description

90
35

13x

Vertical Support Set


(VS) Type

25

ELINEKOVertical and Horizontal Busbar Applications

SLAB

BEAM

100

SLAB

L1

50

L2

WALL

L3
L1

N
PE

100

L2

BUSBAR (FLATWISE POSITION)

L3
N
PE

FIGURE-5 SAMPLE WALL CROSSING WITH FIRE BARRIER

FIGURE-1 FLATWISE POSITION

100

BUSBAR-1

WALL

SLAB

L1
L2

INTERNAL KO-II FIRE


BARRIER MODULE

HOLE

BUSBAR-2

BUSBAR

100

WALL

L3
N
PE

L1
L2

100

EXTERNAL FIRE BARRIER


MATERIAL

L3
N
PE

FIGURE-2 FLATWISE POSITION

FIGURE-4 CROSSING UNDER A BEAM HORIZONTAL POSITION

L1 L2 L3 N PE

100

L1 L2 L3 N PE

WALL

SLAB

200 (min.)
HOLE

WALL

BUSBAR
BUSBAR-1 100

BUSBAR-2

100

FIGURE-3 EDGEWISE POSITION

JOINT POINT

FIGURE-6 STANDARD WALL CROSSING

The dimensions given above are minumum values.

23

ELINEKOVertical and Horizontal Busbar Applications


L1 L2 L3 N PE

L1 L2 L3 N PE

SLAB

20

BEAM

SLAB

200

L1 L2 L3 N PE

VERTICAL EXPANSION
COMPONENT

BUSBAR (EDGEWISE POSITION)

FIGURE-7 CROSSING UNDER A BEAM EDGEWISE POSITION

L1 L2 L3 N PE

200

L1 L2 L3 N PE

WALL

PLUG-IN BUSBAR

TAP-OFF
BOXES

B+100

TAP-OFF
BOXES

WALL

130

150

100

BACK WALL - CURTAIN CONCRETE

FRONT

FRONT WALL

FIGURE-8 MINIMUM DIMENSIONS BETWEEN 2 TAP-OFF BOXES

Neutral conductor position in


housing should be on rightside
from front view at vertical lines.

A = Min distance from front wall


B = Distance to open the cover of Tap off box
C = Depth of Tap off box

The dimensions given above are minumum values. All dimensions are given in mm.

24

SLAB

A= B+C+330

Application of Tap off


box on vertical lines

200

NOTE : To determine the busbar layout


in correct shaft measurement

FIGURE-9
MINIMUM DIMENSIONS ON SHAFT APPLICATIONS

ELINEKOHorizontal And Vertical Expansion Modules Application


Horizontal expansion module ( YDT ) application
It is used for longer horizontal runs as per the pictures shown below (Picture-1)

B
L=39m

B
L=40-60m

B
L<39m

L<39m

L<39m

L<39m

L>60m

B
L>51m

B Feeding point

Line end
Expansion module

L>78m
FIGURE-1 YDT APPLICATION

It is essential that a YDT is used if busbar runs cross a building expansion joint

FIXED
HANGER

200
mm

SLAB

BEAM

BEAM

BUILDING EXPANSION

VERTICAL
EXPANSION
COMPONENT

150cm

FIGURE-2 YDT BUILDING EXPANSION APPLICATION

Vertical expansion modle (DDT) application

BUSBAR
SLAB

FIXED
HANGER

200mm

2-) DDT is used between two fixed supports at every floor crossing.

WALL

1-) DDT is used for vertical lines of multistorey buildings .

FIGURE-3 DDT APPLICATION

25

ELINEKO-

BUSBAR TYPE
CONDUCOR TYPE
BUSBAR CODE
PROTECTION DEGREE
NUMBER OF CONDUCTORS
UNPAINTED / PAINTED
COMPONENT
Y DIMENSION
A DIMENSION

Fire Barriers

KO

B
A (mm): Thickness of Fire Barrier
Y (mm): Centreline of Fire Barrier

Block Joint

er

rri

a
eB

Fir

External fire
resistance sealant
by customer
Floor

Sample Order:
250 A, Copper, IP 55, 5 Conductors
Fire Barrier

KOC 0255-

-STD-150-40

Internal
Fire
Barrier

Fire Barriers
Fire barriers are used to prevent the transition of flame and smoke
from one zone to another in case of fire. The fire barriers prevent the
chimney effect of air insulated busbar.

Dimensioning of Fire Barrier


When placing an order for fire barriers to be installed in the KOthe following information is required :

busbar,

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


2- Centreline dimension of the fire barrier should be measured from the side
without the block joint. (Y mm)
3- There will be no plug-in points at the fire barrier location.
4- EAE Supplies a 300 mm thick fire barrier as standard when wall or floor
thickness is not stated.
5- The minimum length for these special elements with fire barrier is 600 mm.
N

Determination of Special Lengths


After the installation of standard 3m lengths, special lengths shorter than 3m may be required.
The minimum length for these special lengths is 350 mm. Please measure these special lengths as shown below.

Measure A length in cm, to determine the length of


special busbar subtract 12 from A.

X=A-120 (mm)

A
Please call us for more information.

26

X=Length of Special Busbar

ELINEKOKO-

Installation of End Closer

1
4
4

2
4

KO1

Mounting instructions for Joints


1a

2 Figure 3

1a

2a

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.)

4- Tighten the double headed


nut untill upper nut is broken.

2- Introduce bolted and non-bolted ends of


the busbar into each other carefully, until the
cover plate screws can be put in.

3- Fix the joint side cover of the block


joint.

5- Take away the broken nut


and plastic seperator.

6- 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 the screws. Check the position of the
earth conductor when installing KO-II with five conductors.

55 Nm (40lbft)

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-fitting the block joint set.

27

ELINEKODeclaration

CE DECLARATION OF CONFORMITY

Product Group

E-Line KO-II Busbar Energy Distribution System

Manufacturer

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


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

This is to attest, under our sole responsibility, that the aforementioned products conforms with
the determined regulations,guidelines and the below standards.

Standard :

IEC 60439-1
IEC 60439-2

CE - Directive

2006/95/EC Low Voltage Directive

Type Tests include verification of;


1- Temperature-rise Limits (8.2.1)
2- Dielectric Properties (8.2.2)
3- Short-circuit Strength (8.2.3)
4- The Effectiveness of The Protective
Circuit (8.2.4)
5- Clearances and Creepage Distances (8.2.5)
6- Mechanical Operation (8.2.6)
7- Degree of Protection (8.2.7)

8- The Resistance of Insulating Materials to


Abnormal Heat and Fire (8.2.9)
9- Structural Strength (8.2.10)
10- Crushing Resistance (8.2.12)
11- Resistance of Insulating Materials
to Abnormal Heat (8.2.13)
12- Resistance to Flame Propagation (8.2.14)
13- Fire Resistance in Building
Penetration (8.2.15)

E L E K T R K

EAE Elektrik A..

Date

30.12.2006

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


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

28

ELINEKOCertificates

29

ELINEKOProduct Overview
160A 800A BUSBAR SYSTEM
PRODUCT OVERVIEW (E-LINE KO-II)
1-

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 independent
internationally accredited laboratory.
- Manufacturing facility of busbar systems shall have ISO 9001 and ISO 14001 certification.
- 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.

2-

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 required
RAL 7038-Electrostatic painted.

2.1- 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 40C ambient temperature
for both tin plated Aluminium and Copper conductor busbars.

160A: 1sec/rms-10kA, Peak-17kA


250 and 315A: 1sec/rms-15kA, Peak-30kA
400 and 500A: 1sec/rms-30kA, Peak-63kA
600A and above: 1sec/rms-35kA, Peak-73,5kA

2.2- 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 the
average 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 of
tap-off box is inserted.
- Busbar system shall have all necessary accessories (elbows, offsets, panel-transformer connections, reductions, etc). Manufacturer shall supply special dimensioned units in
short 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.
2.3- 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 Conductors :(4 full size conductors + earth conductor + Housing)
c) 5 Conductors :( 5 full size conductors + Housing (earthing) )
d) 5 Conductors :( 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.
2.4- Insulation:
- Busbars shall have air-insulation system.
- Rated insulation voltage of the system shall be 1000 V.
2.5- 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).
2.6- Protection:
- Protection degree of the busbar system shall be minimum IP55.

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3-

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 painted
RAL 3020.

4-

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.

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