E-Line KBC-E-Line KBC-Busbar Systems10 300 A.....6 00 A

R

Copper Conductored Compact Busbar

Contents

Introduction

Design & HorizontalDistribution

Design & VerticalDistribution

Technical Characteristics

Order Code System

Standard Components

Elbows

Standard Components

Flexibles / Expansions

Panel Connections

Selection Feeder Boxes

Fixing Elements

Determination ofSpecial Length

Transformer Connections

Tap-off Boxes

Feeder Boxes

2-3

4

5

6-7

8

9

10-13

14

15

16-17

18-19

20-21

22

23

24-25

26

R

KBA

Standartlar IEC 439-1, IEC 439-2

Kýsadevre (1 sn.) kArms

L

50 50 100 100 100 150 15050

Koruma Sýnýfý IP 42 (aksesuarla IP 54)

Empedans 0,065 0,039 0,032 0,025 0,020 0,017 0,0130,050

Aðýrlýk - Plug-in 17 23 31 38 46 56 6520

Ýzolasyon Gerilimi V IEC 664-1/1000V

Direnç mW/m R

X

Z

mW/m

mW/m

0,057 0,034 0,029 0,021 0,017 0,014 0,0110,043

Anma Akýmý A 800 1250 1600 2000 2500 3000 40001000

L1, L2, L3 mm²

mm²

kg/m

kg/m

mm

525 910 1050 1400 1820 2100 2730700

Ýletken Boyutu 7x75 7x130 2(7x75) 2(7x100) 2(7x130) 3(7x100) 3(7x130)7x100

Frekans Hz 50/60 Hz

Endüktif Reaktans 0,031 0,019 0,016 0,013 0,010 0,009 0,0060,026

Aðýrlýk - Feeder, Bolt-on 16 22 29 36 44 53 6219

Kýsadevre (Dinamik) kA 105 105 220 220 220 264 264105

N 525 910 1050 1400 1820 2100 2730700

800 1000 1250 1600 2000 2500 3000 4000

Alüminyum Ýletken

( h

) K

at Y

ükse

klið

i ( c

m. )

Öze

l Bo

yda

Plu

g-Ýn

Bus

bar

Gen

leþm

e M

od

ülü

( 70

cm

. )

m

K

ð

ö

m

(.

)

ý lý

a

þe

)

an

ý

(

e

c

D

l

AB

Çýk

ýþ Y

ükse

klik

leri

1

k at

Çþ No

sý

. k

ýý

ý

g

ý

P

t

-

k

uu

l

K

Ý

u

n

s

u

Çþ

t

Bub

rN

k a

s

ko

s

a E

ý

k at

Çþ

osý

2 k

N

.ýý

n

e

ý b

i

nYa

yr

g

air

KB A 16 0 0 - T R 4

BUSBAR

ÝLETKEN CÝNSÝ

BUSBAR ANMA AKIMIKORUMA SINIFITÝPÝMODÜL ÝSMÝ

2

R

EAE Electric manufactures, designs and provides

a wide range of busbar systems from 25 A to 6000 A.

Busbar systems have many advantages over wire

and conduit.

Lower total installed cost

Busbar material costs are often equal or less than

wire and conduit.

Lower life cycle cost

Busbar components can be added, deleted or relocated

after the initial installation, saving time and money.

Predictable characteristics

Busbar systems conform to common standards.

Readily published characteristics on busbar

short-circuit ratings, voltage drops, weights and

dimensions can be used.

Fast, flexible engineering

The large number of tap-off points makes it possible

to engineer the power supply systems at an early stage,

even before the final disposition of loads is known.

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 unit.

E-Line Busbar Systems; conform to EN standards

and are tested according to EN 60439-2 (2000).

E-Line Busbar System

Wire Systems

Introduction

Technical Features

3

R

GeneralThe perfect design for high current busbar systemsis the "compact structure" where tin plated, insulatedconductors are tightly placed into the sheet metalhousing (Figure 1).

One bolt joint ensures safety andeasy installationE-Line KB busbars are installed by tightening the"one bolt joint". Belleville spring washers on both endsof the bolt retains the original contact pressure, ensuringa more secure, reliable and maintenance - free joint.E-Line busbar systems are easily installed (Figures 2-3).

* The bolt is tightened to 80 Nm (60 lbft) using the torque spanner.

Heat Transfer"In compact structure" there is no empty space filled withair and heat is easily transferred to the environment by thehousing that works like a heat-shink (Figure 4).

High Short-Circuit EnduranceAs there are no support points in "compact structure"momentum levers are not formed.This feature ensures high short-circuit endurance.

Minimum Voltage DropIn E-Line KB, inductive reactance is very low due toclosely placed conductors (Figures 1-4).The voltage drop comparison of compact and ventilatedbusbar that have same cross sectional area provethe importance of the compact structure (Figure 5).

Standard Prefabricated StructureE-Line KB busbar system can be adapted toany kind of building structure using,space-saving prefabricated components.All necessary components and fitting elementsare manufactured items.

* Special components can be manufactured in one week on request.

No Need For Fire BarrierThere is no risk of chimney effect in E-Line KB's

Figure 3

Figure 4

Figure 2

Insulators

L1

2

3

LLN

PE

Voltage Drop

Line length (m)100 m50 m

0

3

6

9

13,3

Figure 5

KBC1000 Busbar

Section: 700 mm²

Ventilated Busbar

Section: 700 mm²I: 1000A

cos : 0,8 j

Housing, sheet metal - RAL 7038

Insulator layers

Figure 1

Conductors (Cu)

Tin plated

5050

6060

80Nm(60lbft)Torque Spanner

R

Design & Horizontal Distribution

4

While designing an electrical distributionsystem with E-Line KB a few approximatedetails will be necessary.

Location, number, type and approximate ratingsof loads,Transformer rates and short-circuit capacities,Utilization factor=a,System coordination with other distribution system(heat, water, etc ),Determining the route of E-Line KB on layout,If necessary, coordination of E-Line KB Busbar withE-Line KO runs,Deciding on suitable hanger types.

Utilization Factor (a)Utilization factor (a) depends on the type andnumber of loads.It is usually around 0.7 or lower. The utilization factorof a line that supplies electricity to motors and lightingsystems is usually lower than 0.6.It is as low as 0.30 in weld shops of car factories,a can be 1 in lines where only one big load is supplied.

Voltage DropFor practical voltage drop calculation, necessaryvalues, formula and easy calculation methods aregiven on the technical characteristics table on pages 6-7.

Rated CurrentThe current is calculated using the following equation:

Short-CircuitTested short-circuit capacities are given on technicalcharacteristics table on pages 6-7.

Busbar Installation PlanOur distributor's project & design departmentswill help you for preparing the installation plans on

QuantityComponents

Components List

Item

Name : Ercan Yýldýz

Date : 18 / 10 / 1994

Signature:

Project Sample

Pre

pare

d b

y

KBC-II-2050 - STD Busbar (20 x 3m.) 60 m.

2 pc.

1 pc.

1 pc.

1 pc.

1 pc.

1 pc.

1 pc.

1 pc.

1 .pc

1 pc.

1 pc.

8 pc.

6 pc.

1

2

3

4

4

4

5

6

7

8

9

10

11

12

KBC-II-2050 - D Downwards Elbow

KBC-II-2050 - R Right Elbow

KBC-II-2050 - U Upwards Elbow

KBC-II-2050 - L Left Elbow

KBC-II-2050 - P11 Panel Connection

KBC-II-2050 - S10 End Closer

KBC-II-2050 - X85 Special Straight Length

KBC-II-2050 - X105 Special Straight Length

KBC-II-2050 - X107 Special Straight Length

KBC-II-2050 - X176 Special Straight Length

KBC-II-2050 - X142 Special Straight Length

KBB 1650 Tap-off Box

KBB 2550 Tap-off Box

Company : Yener Tekstil

Project : Çorlu Tesisleri

Project No : 0120

Busbar current rating is chosen as equal to or higher

then the calculated IB current.

After the voltage drop calculation if the chosen

current rate is not convenient, a higher rating is

chosen.

B

P.a

Ö3.U.cos jI =

BI

P

U

= Operation current (A)

= Installed load (W)

= Utilization factor

= Supply voltage (V)

a

8 pc. KBB 16506 pc. KBB 2550

54 m. (18 pc. x 3 m.) KBC-II-2050

Design & Vertical Distribution

5

R

Project Design

The details below should be sent to ourProject & Design department.

Location and dimensions of the floor penetration where busbar will be installed.Number, height and ceiling thickness of storeys.(a=..., h=...)Connected load for each storey.Supply type of the vertical line (busbar or cable).

Please send the information to us by fax or e-mailwith a sample drawing like the sample (Figure 1).

As each building's structure is different than the otherfor vertical applications of E-Line KB special projectshas to be designed.The details on this page briefly explain the necessaryinformation for drawing a vertical application project.

AB

( h

) H

eig

ht o

f sto

re m

easu

red

fro

m c

eilin

g to

cei

ling

( c

m. )

Sp

ecia

l Len

gth

Plu

g-in

Bus

bar

Vert

ical

Exp

antio

n

( 70

cm

. )

)e li g

h cke

( a Ci n

t in

ss ( cm. )

Tap

-off

Po

int

1th. Plug

Plu-in

Tp-o

f Box

g a

f

Busbar Joi tn

2th. Plug

Fire B

ar er

r i

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

a= ......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

h=

......

Feeder side,cable or busbar

1. Basement

2. Basement

3. Basement

Figure 1

Ground Floor

1. Floor

2. Floor

3. Floor

4. Floor

5. Floor

6. Floor

7. Floor

8. Floor

9. Floor

10. Floor

I1

I2

I3

I4

I5

I7I6

I9

I10

I8

I11

I12

I13

I 41

Line end

Busbar System

Enterance

1

2

3

4

5

6

7

8

9

10

11

…

N

Basement

Cable System

Technical Characteristics

R

6

Measurements and calculations of fault-loop circuit is done according to EN 60439-2 appendix N2b.

Ue

Ui

Icw

Icw

Ip

Ip

1²I R

Ip

Icw

20R

1R

1X

1Z

R

Z

f

IP

0R

0R

X

X

0Z

0Z(1)

(1)

(1)

(1)

(1)

(1)

(1)

Busbar Code

Rated Current

Short-circuit (peak)

0

0

0

0

Fault Loop Resistance (R PH-N)

Fault Loop Resistance (R PH-PE)

Fault Loop Reaktance (X PH-N)

Fault Loop Reactance (X PH-PE)

Fault Loop Impedance (Z PH-N)

Fault Loop Impedance (Z PH-PE)

Standards

L1, L2, L3, N

PE (for 5 conductors)

Weight - 4 Conductors

Weight - 5 Conductors

Housing Cross Section (Sheet Metal)

PE (for 4 ½ conductors)

Rated Operational Voltage

Conductor Size

Resistance (at Rated Current, at Steady State Op. Temp.)

Reactance (at Rated Current)

Impedance (at Rated Current)

Short-circuit Value of Neutral Conductor (1 sec)

Short-circuit Value of Protective Circuit (1 sec)

Short-circuit Value of Neutral Conductor (peak)

Short-circuit Value of Protective Circuit (peak)

Losses at Rated Current

Short-circuit (1 sec)

20R 20°C (Calculation)

Direct Current Resistance

Impedance

Rated Insulation Voltage

Rated Frequency

Protection Degree

Housing Material 1,50 mm. thick epoxy polyester painted pregalvanized sheet metal RAL 7038

In A 1000 1250 1600 2000 2250 2500

10 12 16 20 23 25

IEC 60439-2

1000

1000

50/60

55

50 50 50 50 50 100

105 105 105 105 105 220

30 30 30 30 30 60

63 63 63 63 63 132

30 30 30 30 30 60

63 63 63 63 63 132

0,0340 0,0255 0,0196 0,0159 0,0170

0,0277 0,0210 0,0160 0,0130 0,0119

0,0519 0,0397 0,0307 0,0254 0,0261

135 183 220 209 242

0,0289 0,0238 0,0183 0,0137 0,0129

0,0438 0,0336 0,0261 0,0218 0,0232

0,0578 0,0445 0,0362 0,0282 0,0291

525 700 910 1120 1050

525 700 910 1120 1050

262,5 350 455 560 525

918 968 1028 1088 1836

7x75 7x100 7x130 7x160 2x(7x75)

28 36 44 52 54

33 42 52 60 64

0,0986 0,0747 0,0564 0,0476 0,0504

0,1270 0,0921 0,0827 0,0731 0,0763

0,1637 0,1210 0,1014 0,0883 0,0923

0,3390 0,2776 0,2324 0,2052 0,1887

0,2339 0,1687 0,1498 0,1418 0,1415

0,4119 0,3254 0,2767 0,2496 0,2359

mm²

mm²

kg/m

kg/m

mm²

mmxmm

mm²

V

V

mW/m

mW/m

mW/m

kA

kA

kA

kA

W/m

kA

kA rms

mW/m

mW/m

mW/m

Hz

mW/m

mW/m

mW/m

mW/m

mW/m

mW/m

Copper Conductor

0,0397

0,0340

0,0550

104

0,0348

0,0432

0,0613

450

450

225

918

6x75

26

31

0,1014

0,1167

0,1569

0,3919

0,2344

0,4567

R

7

Voltage Drop Calculation

Voltage drop of a busbar system can be calculatedwith the following formula taking into account the"a" load distribution constant.

DV=aÖ3.L.I.(R.Cosj+X .Sinj) 101-3

= Voltage Drop (V)

= Load Distribution Constant

= Line Length (m)

= Line Current (A)

= Resistance (mW/m)

= Inductive Reactance (mW/m)

= Load Factor

DV

a

L

I

R

X1Cosj

V

3000 3600 4250 4400 5300 6300

30 36 42 44 53 63

100 100 100 120 120 120

220 220 220 264 264 264

60 60 60 72 72 72

132 132 132 158 158 158

60 60 60 72 72 72

132 132 132 158 158 158

0,0128 0,0098 0,0080 0,0085 0,0065 0,0053

0,0097 0,0062 0,0047 0,0048 0,0042 0,0037

0,0208 0,0160 0,0134 0,0139 0,0120 0,0113

274 257 272 289 365 456

0,0101 0,0066 0,0050 0,0050 0,0043 0,0038

0,0184 0,0148 0,0125 0,0130 0,0113 0,0106

0,0236 0,0179 0,0144 0,0157 0,0130 0,0122

1400 1820 2240 2100 2730 3360

1400 1820 2240 2100 2730 3360

700 910 1120 1050 1365 1680

1936 2056 2176 2904 3084 3264

2x(7x100) 2x(7x130) 2x(7x160) 3x(7x100) 3x(7x130) 3x(7x160)

70 86 102 104 128 152

82 102 118 122 152 187

0,0348 0,0286 0,0220 0,0251 0,0201 0,0175

0,0520 0,0475 0,0471 0,0411 0,0450 0,0421

0,0632 0,0561 0,0521 0,0486 0,0495 0,0456

0,1964 0,1361 0,1190 0,1191 0,1086 0,0932

0,1016 0,1031 0,0947 0,0908 0,0867 0,0680

0,2224 0,1708 0,1522 0,1499 0,1391 0,1154

Load Distribution Factor

L

L1

L1

L1

L1

L2

L2

L2

L3

L3

L3

L2

L4

L4

L4

F

F

F

F

FF

L

F= Supply

L= Load

F= Supply

L1,L2,L3,L4

Load

F= Supply

L1,L2,L3,L4

Load

F= Supply

L1,L2,L3,L4

Load

F= Supply

L1,L2

Load

1.00

0.50

0.125

0.25

0.25

a

Standard LengthSpecial Length Upwards ElbowDownwards ElbowRight ElbowLeft Elbow

Upwards Vertical OffsetDownwards Vertical OffsetRight Horizontal OffsetLeft Horizontal OffsetRight Upwards Combined Offset Left Upwards Combined Offset Right Downwards Combined OffsetLeft Downwards Combined OffsetUpwards Right Combined OffsetUpwards Left Combined OffsetDownwards Right Combined OffsetDownwards Left Combined Offset

Left Side Feeder "T"Right Side Feeder "T"Central Feeder "T"

Horizontal ExpansionVertical Expansion

ReductionEnd CloserEnd Closer

Panel ConnectionPanel ConnectionUpwards Panel ConnectionUpwards Panel ConnectionDownwards Panel ConnectionDownwards Panel ConnectionRight Panel ConnectionRight Panel ConnectionLeft Panel ConnectionLeft Panel ConnectionPanel ConnectionPanel Connection

Transformer ConnectionUpwards Transformer ConnectionDownwards Transformer ConnectionTransformer ConnectionTransformer ConnectionRight Transformer ConnectionLeft Transformer ConnectionTransformer Connection

Feeder BoxFeeder BoxCentral Feeder Box

Flexible

STDX

UDRL

UVDVRHLHKRUKLUKRDKLDKURKULKDRKDL

TYLTYRTO

YDTDDT

RDS10S11

P10P11PU20PU21PD20PD21PR30PR31PL30PL31P40P41

TR11TU21 TD21 TR31TR41 TR51TL51TR61 B10B11BO

F

Order Code System

8

R

*TYPE

Bolt-on

Plug-in

Feeder

Utilization Type

Energy is suplied

from the joints.

Energy is supplied either

from the joints or the

plug-in points.

Used where there is no need

to use tap-off boxes.

COMPONENTS

TYPE*

PROTECTION DEGREE

BUSBARCODE

IP 55 5

Bolt-onPlug-inFedeer

012

Conductors 4 5 4+ ½

345

678

Busbar Type

Cu

Conductor

Conductor

Size

RatedCurrent

BusbarCode

16 5 0 T R 4 1

BUSBAR TYPE

BUSBAR CODE

PROTECTION DEGREE

UTILIZATION TYPE

COMPONENT

1000

1250

1600

2000

2250

2500

3000

3600

4250

4400

5300

6300

10

12

16

20

23

25

30

36

42

44

53

63

6 x 75

7 x 75

7 x 100

7 x 130

7 x 160

2 x (7 x 75)

2 x (7 x100 )

2 x (7 x130 )

2 x (7 x160 )

3 x (7 x100 )

3 x (7 x130 )

3 x (7 x160 )

Sample Order:2500 A, ,Bolt-on, 4 Conductors

Copper

Sample Order:2000 A, Copper, Bolt-on,4 Conductors

Sample Order:1000 A, Copper

B=.....mmX=.....mmY=.....mmZ=.....mmø=.....mm

This side is punched accordingto the needs of the custommer.

L(cm)

Used at every 40 m in horizontallong lines and for crossing buildingexpansions.

For vertical application in many storeybuilding.

Transformer - busbar,

Panel - busbar connections.

One vertical expansion unit is advisedto be used at every floor betweenfixed support points.

Horizontal Expansion

Vertical Expansion

Flexibles

Horizontal Expansion

Vertical Expansion

Flexible are used for

- Y D T

- D D T

- F

Flexibles & Expansions

Please call us for non-standard components.

**

Y

LB

Z

X

700

1500

L1L2L3N

L1L2L3N

15

-2550 - YDT

-2050 - DDT

-1000 - F40

BUSBAR TYPE

BUSBAR CODE

PROTECTION DEGREE

UTILIZATION TYPE

COMPONENT

Fixing Elements

ORDER CODELENGTH L (mm)

Supports

R

Please call us for non-standard components.

25

PDD 300400...2000

UDD

STSSTS

TMP 5

UDY

PDDB

STK

BRA 12-05BRA 12-10BRA 14-05BRA 14-10BRA 13BRA 13

BRA 9-3BRA 9-4

Threaded RodThreaded RodThreaded RodThreaded RodExstension UnitExstension Unit

Steel DowelSteel Dowel (M12)

(M10x500) (M10x1000) (M12x500) (M12x1000) (M10) (M12)

(M10)

UDY

STS

300400...1000

200300400

300400-----2000

200300400

PDD PDD

PDDBPDDB

STK

IDD

STK

UDYL

L

ExstensionUnit

SteelDowel

Threaded Rods

L

Determination of Special Length

After the installation of standard 3m lengths, you will be in need of special

lengths which are smaller than 3m. The minimum length for these special

elements can be 35 cm. Please measure the lengths of these modules as shown

below.

busbar

"A" length should be indicated in cm. Measure the asistance from one end of the

side housing to the other.

A=Length of Special Busbar

A

R

26

27

Project Design FormQ

uantit

yC

om

po

nen

t

Co

mp

on

en

t Lis

t

Item

Nam

e :

Date

:

Sig

natu

re :

Prepared by

Co

mp

an

y

:

Pro

ject

:

Pro

ject

No

:

Ple

ase

du

blic

ate

th

is p

ag

e fo

r yo

ur

ow

n u

se.