CR El Kitabi

EAE Elektrik A.S.
E-LINECR MANUAL
Akcaburgaz Mahallesi,
3114. Sokak, No:10 34522
Esenyurt - Istanbul
Tel: +90 (212) 866 20 00
Fax: +90 (212) 886 24 20
MENTAL MAN
ON
V IR
AG
s
E
ISO
A N D EN
MENT SYSTE
IEC 61439-6 9001 T E

ITY
14001
AL
E 344805
M
QU S
CR Manual Eng. / Rev 02 1.000 pcs. 27/02/2020

G.M.
EAE has full right to make any revisions or changes on this catalogue without any prior notice.
www.eaeelectric.com
E-LINECR
INDEX
Introduction 2
Unloading, Handling and Storage of Products 3
Joint Area General Information 3
Handling and Lifting 4-5
Project Design 6
Horizontal & Vertical Cast Resin Busbar Applications 7
Suspension Components 8-11
Equipment Used 12
Horizontal Edgewise Mounting Application 13-14
Resin Application on Horizontal Edgewise During Assembly 15
Horizontal Mounting Application 16-17
Resin Application Horizontal During Assembly 18
Vertical Mounting Application 19-20
Resin Application Vertical During Assembly 21
Preparation of Joint Casting Material 22
Electrical site-tests 23
Junction Resistance Test Report 24
Line Insulation Resistance Test Report 25
Declaration 26
Certificates 27
Product Overview 28
CRMANUAL
Introduction
Dear Customer,
EAE Elektrik A.S. 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 ISO 9001 standards in their modern production plants in Istanbul .
The components that you have purchased are manufactured by 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.
2
CRMANUAL
Unloading, Handling and Storage of Products
Unloading:
§ Forklift is the most reliable and easiest method for the unloading of the products from the container or
the truck arriving at the worksite.
§ Utmost care is required to be exercised to ensure avoidance of any harm that can be sustained by the
products during the unloading process.
Storage:
§ From the packing list check the number of pallets received, the number, dimensions and the condition
of the busbar lengths. Advise any discrepancies immediately to the local EAE representative.
§ All products should be stored in a dry environment. The casting materials for the joint must be stored
at a temperature between 5 °C and 25 °C and not exposed to direct sunlight
Handling:
§ Do not handle the materials using steel ropes or hooks. As shown in the castresin busbar should be
lifted using lifting straps placed at each end of the busbar length.
§ Short modules may be lifted using a single strap providing that the piece is balanced.
§ A wooden spacer should be used every 1.5m when storing the lengths placed on top of each other.
§ Do not stack more than 5 modules on each other horizontally.
Joint Area General Information

Joint Area Processing and Casting:
§ Wait for a while before process.
§ For vertical applications the mould sides should be tightened or supported to prevent the mould
slipping down.
§ Type C hardener shall be used if the ambient temperature is 5 to 15 °C; and type B shall be used if the
ambient temperature is 15 to 35 °C.
§ The expiry dates of the resin and hardener should be checked. They should not be used if the expiry
date has passed.
§ Ensure that the sand additive is dry.
§ The mixture should be stirred for at least 5 minutes until thoroughly mixed.
§ The mixture should be poured into the joint to the top of the mould, it should not be allowed to overflow.
§ Joint moulds may be removed after 3 hours at 25 °C, 4 hours at 15 °C and 6 hours at 5 °C.
§ Inside of the joint mould material shall be cleaned with a cloth; do not use a solvent or a metal cutting
tool.
Pre-Cast Controlling of Juncture Area:

§ The final check form supplied should be completed for each busbar joint installed.
§ Perform a megger test after each joint, and ensure that there is no problem on the joint area.
§ In order to prevent damage to the terminals and transformers during this test, remove their
connections or protect them.
§ After every electrical test, the system must be discharged to earth.
§ After completing all electrical tests, make the terminal, MCCB and fuse connections again.
§ The form filled in after each test should be submitted to the EAE representative. The product quality
approval form (186) should be completed and submitted to us to validate the warranty.
3
CRMANUAL
Handling and Lifting
Strapping type ropes should

only be used instead of round
ropes to prevent the materials
slipping during handling.
Short modules can be handled by a single rope,

however, ensure that it is balanced.
A wooden wedge shall be used every 1.5 m when the
materials are placed on each other while storing
them.
Do not put more than 5 modules on each other
horizontally.
1500 mm 1500 mm
4
CRMANUAL
Handling and Hanging
Introduction:
This installation manual includes the details of safe and quick handling and installation of cast resin
busbar product. It shall be read carefully before starting the procedures on the product and relevant
steps shall be followed.
Things To Do:
1- Read the info note on the pallet; lift and handle the the product as shown in "Figure 1" taking the pallet
weight into consideration.
2- Product shall be hanged and lifted as shown in "Figure 2" while it is handled. (Figure 2)
3- Resin and hardener shall be stored as shown in Figure 3.
4- Busbar route shall be marked before starting the installation.
5- Installation shall start from a single point (preferably panel) and shall be completed with the last
module.
6- Do not perform casting before performing megger test on the joint and observing infinite resistance
as the result of the test.
7- Do not apply expired joint casting agent.
Figure 1 Figure 2 Figure 3
5
CRMANUAL
Project Design
A A
m n.=25cm
m n.=25cm
m n.
400
m n.
25cm
Rated Current 630 800 1000 1250 1600 2000 2500 2250 2500 - 3000 3200 3600 4000 5000
CRA - Al (A)
Conductor Busbar Code 06 08 10 12 16 20 25 23 27 - 30 33 36 40 50
Rated Current 800 1000 1250 1600 2000 2500 - 3000 3200 3600 4000 - 5000 - 6300
CRC - Cu (A)
Conductor Busbar Code 08 10 12 16 20 25 - 30 32 36 40 - 50 - 63
A (mm) 90 105 130 160 210 250 300 310 340 370 410 430 490 590 730
6
CRMANUAL
Horizontal & Vertical Cast Resin Busbar Applications
FIGURE 1 - EDGEWISE APPLICATION FIGURE 5 - CROSSING UNDER A BEAM ON

CEILING FLATWISE APPLICATION
500 CEILING
BEAM
100
200
WALL
PE
BUSBAR RUNNING ON FLATWISE L3
L2
PE L3 L2 L1 N APPLICATION L1
N
FIGURE 2 - EDGEWISE APPLICATION FIGURE 6 - SAMPLE WALL CROSSING

CEILING WITH FIRE BARRIER
WALL
500
HOLE
PE L3 L2 L1 N
200 BUSBAR-2 BUSBAR
WALL
200
EXTERNAL FIRE BARRIER

PE L3 L2 L1 N
MATERIAL
200 BUSBAR-1
Primarily on the installation phase;

Busbar-1 line should be installed before Busbar-2 line.
FIGURE 3 - FLATWISE APPLICATION FIGURE 7 - STANDARD WALL CROSSING

CEILING
WALL
500
500
350 (min.)
HOLE
200
BUSBAR
WALL
BUSBAR-1 BUSBAR-2
200 CENTRE LINE
PE PE OF JOINT
L3 L3
L2 L2
L1 L1
N N
Primarily on the installation phase;

BUSBAR-1 line should be installed before BUSBAR-2 line.
FIGURE 4 - CROSSING UNDER A BEAM ON EDGEWISE APPLICATION

Attention !
CEILING
For correct installation, the dimension from the busbar to
the ceiling should not be less than 500mm
BEAM
The joint should be not come across to Beams.

100
PE L3 L2 L1 N The dimensions given above are minimum values.

BUSBAR RUNNING ON EDGEWISE
APPLICATION AS STANDARD
All dimensions are given in mm.
7
CRMANUAL
Suspension Components
SUPPORTS
CR-UT HANGER SET FOR EDGEWISE APPLICATION (STANDARD APPLICATION)
Conductor
CRA - Al CRC - Cu Cross
Order
Conductor Conductor L A
Section Code
Rated Busbar Rated Busbar (mm) (mm)
Current Code Current Code
630 06 800 08 6x40 300 90 3025348
800 08 1000 10 6x55 300 105 3025348
1000 10 1250 12 6x80 300 130 3025348
1250 12 1600 16 6x110 350 160 3025348
1600 16 2000 20 6x160 400 210 3025348
2000 20 2500 25 6x200 400 250 3025348
2500 25 - - 6x250 450 300 3025348
A
43 65
4
L
CR-UT HANGER SET FOR FLATWISE APPLICATION (NON-STANDARD APPLICATION)
CRA - Al CRC - Cu Conductor Order

Conductor Conductor Cross L A Code
Section
Rated Busbar Rated Busbar (mm) (mm)
Current Code Current Code
630 06 800 08 6x40 350 90 3025347
800 08 1000 10 6x55 350 105 3025347
1000 10 1250 12 6x80 350 130 3025347
1250 12 1600 16 6x110 350 160 3025347
1600 16 2000 20 6x160 350 210 3025347
2000 20 2500 25 6x200 350 250 3025347
2500 25 - - 6x250 350 300 3025347
65
4
L
*Flatwise Application is supplied for only on special conditions. Please call us for non-standard dimensions.
8
CRMANUAL
SUPPORTS
CR HANGER SET WITH BRACKETS FOR CR HANGER SET WITH BRACKETS FOR
EDGEWISE APPLICATION EDGEWISE APPLICATION
(Standard Application) (Non-Standard Application)
5 5
50 50 50 50
L L
UAS-K5 Supports
Description L Order Code
(mm)
L
UAS-K5 Support (1) 200 3005324
L
UAS-K5 Support (2) 250 3005323
50 UAS-K5 Support (3) 300 3005322
5 50 UAS-K5 Support (4) 350 3005321
Threaded Rod UAS-K5 Support (5) 400 3005320
UAS-K5 Support (6) 500 3005319
UAS-K5 Support (7) 600 3005318
UAS-K5 Support (8) 700 3005317
Extension Unit UAS-K5 Support (9) 1100 3005316
Connection Units
(mm)
BRA 12-05 Threaded Rod (M10) 500 5000037

Steel Dowel BRA 12-10 Threaded Rod (M10) 1000 5000032
Diameter of the
Hole to be drilled BRA 14-05 Threaded Rod (M12) 500 5000026
M10.....Ø14
BRA 14-10 Threaded Rod (M12) 1000 5000034
M12.....Ø16
BRA 13 Extension Unit (M10) - 1004312
Steel Nut BRA 13 Extension Unit (M12) - 1004282
BRA 9 Steel Dowel (M10) - 5000023
BRA 9 Steel Dowel (M12) - 5000022
Washer M10 Steel Nut - 1000522

M12 Steel Nut - 1000964
M10 Washer - 1000504
Please call us for non-standard dimensions. M12 Washer - 1000505
9
CRMANUAL ORDER CODE
LENGTH L (mm)
SUPPORTS

(mm)
IDY 300 300 3008242

IDY 400 400 3008290
IDY IDY 500 500 3008289
24 IDY 600 600 3008288
IDY 700 700 3008287
L IDY 800 800 3008286
IDY 900 900 3008285
IDY 1000 1000 3008284
IDY 1100 1100 3008283
IDY 1200 1200 3008282
IDY 1300 1300 3008236
IDY
75 IDY 1400 1400 3008281
IDY 1500 1500 3008280
IDY 1600 1600 3008241
IDY 1700 1700 3008240
IDY 1800 1800 3008239
IDY 1900 1900 3008238
IDY 2000 2000 3008237
IDD 300 300 3008314

IDD 400 400 3008313
IDD 500 500 3008312
IDD 600 600 3008311
IDD 105 155
IDD 700 700 3008310
IDD 800 800 3008309
IDD 900 900 3008308
IDD 1000 1000 3008307
5
5x3 IDD 1100 1100 3008306
Ø1 IDD 1200 1200 3008305
IDD 1300 1300 3008304
L IDD 1400 1400 3008303
IDD 1500 1500 3008302
IDD 1600 1600 3008301
IDD 1700 1700 3008300
IDD 1800 1800 3008299
IDD IDD 1900 1900 3008298
IDD 2000 2000 3008297
IDT Support Fitting - 3008279
IDT
IDY
IDT
IDT
Please call us for non-standard dimensions.
10
CRMANUAL ORDER CODE
LENGTH L (mm)
SUPPORTS
UPY
Steel
Dowel T
L
Threaded
Rod
65
UPY 43
Description T L Order Code

(mm) (mm)
UPY 300 4 300 3004487

UPY 400 4 400 3004489
Steel
UPY 500 4 500 3004491
Dowel
UPY 600 4 600 3004493
UPY 700 4 700 3004495
Threaded UPY 800 4 800 3004496
Rod UPY 900 4 900 3004497
UPY 1000 4 1000 3004498
UPY 1100 4 1100 3004499
UPY 1200 4 1200 3004500
UPY 1500 4 1500 3004503
UPY
Please call us for non-standard dimensions.
11
CRMANUAL
Equipment Used
1 2 3 4
Fabric Crane Ropes Torque Wrench Hot Air Blower Spirit Level
5 6 7 8
Nut Set Socket Set Wrench, Screwdriver Lifting Device

(forklift truck, crane, hoist etc.)
9 10 11 12
Megger Device Dielectric Test Device 5 kV DC Paint Brush Scaffold
13 14 15 16
Mixer Putty knife Protective Clothes, Drill

Gloves, Goggles
12
CRMANUAL
Horizontal Edgewise Mounting Application
1 2
Stretch and head plastic at the tip of the busbar Tip parts exposed on the busbar are required to be
shall be removed. cleaned with a clean and dry piece of cloth. After the
completion of the cleaning process, it is aligned with
It is alinged with the block joint and mounted on the
stationary busbar.Block joint bolt shall be slightly
tightened for not to falling
3 4 mm
250
Second busbar is brought into alignment with the Coupled busbars and block joint shall be put into
block joint. The block joint shall be loosened, and the final form by looking at the alignments there of.
second busbar shall be mounted on the stationary Torqued with the torque wrench by setting to 83 Nm.
busbar. Bolt clearance is removed tightened slightly.
5 6
MW
Megger test shall be conducted among the entire Inner surfaces of molds (surfaces subject to casting
phases. process) shall be cleaned with a clean and dry piece
of cloth.
13
CRMANUAL
Horizontal Edgewise Mounting Application
7 8
mm
70
Block joint moulds shall be brought on the coupled Alloy shall be casted uninterruptedly from the same
busbars and affixed accordingly. Block joint moulds spot.
shall be secured on the trays with bolts with a (Please refer to page 22 for alloy preparation guide.)
distance of 70 mm from the tip of the busbar.
9 10
Vibration is provided by means of plastic hammer. For each juncture, brushing for 2 minutes shall be
performed once in every 10-15 minutes throughout
1 hour.
x
11 12
After the curing of the material (6-12 hours), casting Megger test should not be conducted for a
mold shall be removed, and the sharpness of the minimum of 12 hours after the casting process.
part shall be smoothed accordingly.
(Note: Varies depending on the seasonal conditions
and temperature. Cold weather is disadvantageous.)
14
CRMANUAL
Resin Application on Horizontal Edgewise During Assembly
Horizontal Application
After the entire adjustments are made, megger test and dielectric test shall be
conducted on the busbar system coupled and absence of any stray voltage shall be
ensured accordingly. Material prepared in buckets shall be casted on juncture area.
Material casting shall be ensured not to have any clearance at all. After the
completion of casting process, the material shall be ensured to be placed tightly by
slightly hammering the block joint moulds.
After the block joint mould is filled up to the upper level, the surface is required to
be levelled out with a brush.
For the purpose of expediting the air outlet after the completion of the casting
process, vibration rendering process shall be applied on the mold for 8-10
minutes by a plastic hammer.
Casting surface shall be brushed once in every 10-15 minutes and air bubbles
forming shall be removed and the surface shall be smoothed accordingly.
To remove the block joint mould, it shall be waited for curing process of 6-12
hours and the complete stiffening to be completed.
In case of a requirement of more than 1 dose of application in the application of
the juncture resin, it shall be performed successively without waiting for the
application of the 2nd and the 3rd doses.
Note: Material for each joint shall be prepared separately and this
prepared material shall be poured within 15 minutes.
15
CRMANUAL
Horizontal Mounting Application
1 2
the block joint tray and mounted on the stationary
busbar. Block joint bolt shall be slightly tightened for
not to falling.
3 4 mm
250
block joint. The block joint shall be loosened, and the final form by looking at the alignments thereof.
5 6
MW
of cloth.
16
CRMANUAL
Horizontal Mounting Application
7 8
mm
70
Block joint molds shall be brought on the coupled Alloy shall be casted uninterruptedly from the same
trays and affixed accordingly. Juncture molds shall spot.
be secured on the trays with bolts with a distance of (Please refer to page 22 for alloy preparation guide.)
70 mm from the tip of the busbar.
9 10
1 hour.
x
11 12
17
CRMANUAL
Resin Application Horizontal During Assembly
Horizontal Application
To remove the juncture mold, it shall be waited for curing process of 6-12 hours
and the complete stiffening to be completed.
Note: Material for each joint shall be prepared separately and this
prepared material shall be poured within 15 minutes.
18
CRMANUAL
Vertical Mounting Application
1 2
the block joint tray and mounted on the stationary
busbar. Block joint bolt shall be slightly tightened for
not to falling.
3 4
mm
250
block joint. The block joint shall be loosened, and the final form by looking at the alignments there of.
5 6
MW
of cloth.
19
CRMANUAL
Vertical Mounting Application
7 8
The support sheet delivered to assist that the block The alloy shall be casted uninterruptedly from the
joint mold maintains its position shall be affixed. sheet that are delivered to assist the casting process
Block joint molds shall be brought on the support from the same spot.
sheet and secured by means of bolts in a manner (Please refer to page 22 for alloy preparation guide.)
that the gaskets shall be at the bottom.
9 10
1 hour.
x
11 12
20
CRMANUAL
Resin Application Vertical During Assembly
Vertical Application
To remove the block joint mould, it shall be waited for curing process of 6-12
hours and the complete stiffening to be completed.
Note: Utmost care should be exercised for the alignments in vertical
applications. Otherwise, clearances
may form on the upper part to risk the
juncture accordingly.
21
CRMANUAL
Preparation of Joint Casting Material
Megger test is definitely required to be conducted prior to
the casting process.
< 5°C STOP
Resin (A), Hardener (B) and fillers; must be stored at least
< 35°C STOP
one day over (> 20 °C ).
MW
Ambient temperature of job side must be 5°C < T amb <40°C
< 1MW OK T(°C)
< 1MW NOT OK
Preparation of Cast Resin Mixture
350 mm
150 mm + 100 mm
FILLER RESIN (A) HARDENER (B)
1 2 A 3
A
B
Filler removed from the plastic bucket. Resin and hardener are mixed in plastic bucket.
4 5
Mix resin and hardener thoroughly with stirrer Add fillers and mix until homogeneous; at least 5
at least 1 minute. minutes.
Then application must be done within 15 minutes.
22
CRMANUAL
Electrical site-tests
Junction Resistance Test
Cu
rre
Vo nt p
lta rob
ge e (-)
pro
Vol be
ta (-)
Cu ge
rre pro
nt p be
rob (+)
e (+)
Rmax ≤ 1,5 mΩ
Line Insulation Resistance Test
< 5°C STOP

< 35°C STOP
MW
≥ 1MW OK T(°C)
< 1MW NOT OK
23
CRMANUAL
EAE Electrical Site Test Report
Junction Resistance Test Report
Customer: Date: ........./ ......../ ............

Project: Order No: .................................
Address: Un : V In : A
Busbar Code: Mater al: AL CU Conductor Sect on: ........... x .......... mm2
L ne: Requ red Torque: M12 83Nm
Note: The tests have to perform only w th cal brated dev ces. Cal brat on Date: ......../ ......../ ............
Results
Junct on: Junct on: Junct on: Junct on: Junct on:
Phase R (µΩ) Phase R (µΩ) Phase R (µΩ) Phase R (µΩ) Phase R (µΩ)
N-N N-N N-N N-N N-N
L1 - L1 L1 - L1 L1 - L1 L1 - L1 L1 - L1
L2 - L2 L2 - L2 L2 - L2 L2 - L2 L2 - L2
L3 - L3 L3 - L3 L3 - L3 L3 - L3 L3 - L3
PE - PE PE - PE PE - PE PE - PE PE - PE
Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm
Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ
Junct on: Junct on: Junct on: Junct on: Junct on:
Phase R (µΩ) Phase R (µΩ) Phase R (µΩ) Phase R (µΩ) Phase R (µΩ)
N-N N-N N-N N-N N-N
L1 - L1 L1 - L1 L1 - L1 L1 - L1 L1 - L1
L2 - L2 L2 - L2 L2 - L2 L2 - L2 L2 - L2
L3 - L3 L3 - L3 L3 - L3 L3 - L3 L3 - L3
PE - PE PE - PE PE - PE PE - PE PE - PE
Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm Torque: ....... Nm
Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ Max Value: ........ µΩ
The max mum values per type and explanat on to execute th s test can be found n Annex A Elect rcal S te Tests of CR Manuel
Remarks
W tnesses
Name Company Date S gnature
24
CRMANUAL
EAE Electrical Site Test Report
Line Insulation Resistance Test Report
Customer: Date: ........./ ......../ ............

Project: Order No: .................................
Address: Us : V Is : A
Busbar Code: Mater al: AL CU Conductor Sect on: ........... x .......... mm2
L ne: Result by: ................ V (DC)
Note: The tests have to perform only w th cal brated dev ces. Cal brat on Date: ......../ ......../ ............
Recommended Test Voltage 5000 V DC
Insulat on Res stance ≥ 1000 Ω/V
Results
PE L3 L2 L1 N
Before Casting After Casting
N - L1 = .............................................. / .............................................. MΩ
N - L2 = .............................................. / .............................................. MΩ Standard Conductor

Configuration
N - L3 = .............................................. / .............................................. MΩ
N - PE = .............................................. / .............................................. MΩ
L1 - L2 = .............................................. / .............................................. MΩ
L1 - L3 = .............................................. / .............................................. MΩ
L1 - PE = .............................................. / .............................................. MΩ
L2 - L3 = .............................................. / .............................................. MΩ
L2 - PE = .............................................. / .............................................. MΩ
L3 - PE = .............................................. / .............................................. MΩ
Remarks
W tnesses
Name Company Date S gnature
25
CRMANUAL
Declaration
CE DECLARATION OF CONFORMITY
Product Group E-Line CR Busbar Energy Distribution System
Manufacturer EAE Elektrik Asansor End. Insaat San. ve Tic. A.S.

Akcaburgaz Mahallesi, 3114. Sokak,
No:10 34522 Esenyurt-Istanbul
The objects of the declaration described below is in conformity with the relevant Union harmonisation
legislation. This declaration of conformity is issued under the sole responsibility of the manufacturer.
Standard :
EN 61439-6
Low-voltage switchgear and controlgear assemblies - Part 6: Busbar trunking
systems
IEC 61439-6
Low-voltage switchgear and controlgear assemblies - Part 6: Busbar trunking
systems (busways)
CE - Directive
2014/35/EU “The Low Voltage Directive”
2014/30/EU “Electromagnetic Compatibility (EMC) Directive”
2011/65/EU “Restriction of the use of certain hazardous substances (RoHS)”
Technical Document Preparation Official ;
EAE Elektrik Asansor End. Insaat San. ve Tic. A.S.

Akcaburgaz Mahallesi, 3114. Sokak, No:10 34522 Esenyurt-Istanbul
Emre GÜRLEYEN
Date Document Authorized Signatory
20.04.2016 Elif Gamze KAYA OK

Deputy General Manager
26
CRMANUAL
Certificates
27
CRMANUAL
Product Overview
630A ... 6300A COMPACT BUSBAR

PRODUCT OVERVIEW (E-LINE CR)
1- Standards & Certification:
-Busbar system shall be designed and manufactured as per IEC 61439-6 standard, which requires below listed tests. Each busbar rating
shall have a separate type test certificate from an independent internationally accredited laboratory including below tests:
2- Electrical Characteristics
- Busbar systems nominal insulation voltage shall be 1000 V.
- As per ampere rates, minimum short circuit values shall be as given below;
For Aluminium Conductors; 630A : 1 sec/rms 20kA, Peak 40kA
800A : 1 sec/rms 28kA, Peak 58,8kA
1000A : 1 sec/rms 40kA, Peak 84kA
1600-2000-2500A : 1 sec/rms 70kA, Peak 154kA
3000A and above : 1 sec/rms 120kA, Peak 264kA
For Copper Conductors; 800A : 1 sec/rms 23kA, Peak 48,3kA
2000-2500A : 1 sec/rms 80kA, Peak 176kA
3000A and above : 1 sec/rms 120kA, Peak 264kA
2.1- Housing
- Special cast resin material shall be used as housing of the conductors.
- All conductors shall be plated with tin.
- Expansion units shall be used in building expansion areas and also vertical lines higher than 40 m.
2.2- Conductors
Aluminium or Copper conductors shall be tin plated at the joints upon the wire configuration and required numbers, which are described
below.
- Busbar system shall have aluminium conductors between 630A – 5000A.
- Busbar system shall have copper conductors between 800A – 6300A.
- Busbar system shall have the following number of conductors and wire configuration;
a) 3 Conductors
b) 4 Conductors
c) 4 ½ Conductors
d) 5 Conductors
e) 6 Conductors
- Aluminium conductors shall be of EC grade aluminium. Minimum conductivity shall be 34m/mm².W.
- Copper conductors shall be minimum 99,95% electrolytic copper. Minimum conductivity shall be 56m/mm².W.
2.3- Insulation
- Busbars have to be insulated special selected silica and calcile mixed with electrical grade epoxy resin to make superior composite.This
material continuosly works under temperature change and movements.
- Insulation system shall be suitable for 1.000V continuous operation. Conductor size shall be designed so that temperature rise on the
conductors shall not exceed 100 C degree at nominal current, which helps with the problem of global heating. With this reason, insulation class
shall be “B class”.
2.4- Protection
- Protection degree of the housing and joints shall be IP68
2.5- Acessories
- 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.
3- Installation and Commisioning
- Busbar systems shall be installed as per Single-Line drawings with respect to the required ampere rates and the manufacturer’s installation
guide (torque values, lockers, etc.). The electrical installer shall run an insulation test after installation according to the manufacturer’s test
procedures. The results of the test shall be reported to the manufacturer. Minimum insulation value shall be 1 Mohm.
28
PRODUCT TYPES
BUSBAR ENERGY DISTRIBUTION SYSTEMS
CABLE TRAYS
TROLLEY BUSBAR ENERGY DISTRIBUTION SYSTEMS
INDOOR SOLUTIONS
SUPPORT SYSTEMS
Please visit our website for the updated version of our catalogues.
www.eaeelectric.com
IRAQ
OMAN
SUDAN
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YEMEN CHILEALGERIA PERU
OMAN TURKMENISTAN TURKEY
INDIA MADAGASKAR
SRI LANKA LATVIA
ETHIOPIA
FRANCE TAIWAN
GHANA UKRAINE
JAN VIETNAM
KONGO
CAMEROON ESTONIA FINLAND KUWAIT
UM IRELAND
BANGLADESH KUWAIT
THAILAND QATAR
UZBEKISTAN SYRIA ALGERIA CHINA
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ONIA TANZANIA MADAGASKAR
MOROCCO
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PAKISTAN ROMANIA QATA
BELGIUM AUSTRIA GERMANY KENYA
SINGAPORE TANZANIA
TAN CZECH REP. ETHIOPIA PERU EQ. GUINEA TURKEY OMAN VIETNAM LATVIA MACED
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TANZANIA MACEDONIA MADAGASKAR TUNISIA AZERB
POLAND TURKMENISTAN
KAZAKHSTAN NIGERIA LUXEMBOURG RWANDA GREECE SYRIA CROATIA SOUTH KOREA SWIT
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SLOVENIA
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EGYPT FRANCE ETHIOPIA CAMEROON PAKISTAN
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SPAIN EGYPT VIETNAM SUDANMADAGASKAR NETHERLANDS
TURKEY NIGERIAITALYRUSSIA U.KINGDOM TAIWAN
BAHRAIN SWITZERLAND U. A. EMIRATES BULGARIA SOUTH AFRICA QATAR TURKEY GREECE PAKISTAN D
ULGARIA GHANATURKMENISTAN
GREECE SRI LANKA
CYPRUSBELARUS AZERBAIJAN
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VIETNAM NORWAY SERBIANORWAY SPAIN FRANCE DENMARK M
NIGERIA POLAND U. A. EMIRATES
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A. EMIRATES CHILE
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SUDAN SWITZERLAND U. A. EMIRATES MALTA SU
MACEDONIA TANZANIA MADAGASKA
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ANMAR SAUDI ARABIA YEMEN BRASIL BELGIUM POLAND BELGIUM U.KINGDOM TURKMENISTAN CZECH REP. AZERBAIJAN DENMARK
OVENIA RUSSIAYE

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EAE Elektrik A.S.

IEC 61439-6 9001 T E

CR Manual Eng. / Rev 02 1.000 pcs. 27/02/2020

Unloading, Handling and Storage of Products 3

Joint Area General Information 3

Handling and Lifting 4-5

Horizontal & Vertical Cast Resin Busbar Applications 7

Suspension Components 8-11

Horizontal Edgewise Mounting Application 13-14

Resin Application on Horizontal Edgewise During Assembly 15

Horizontal Mounting Application 16-17

Resin Application Horizontal During Assembly 18

Vertical Mounting Application 19-20

Resin Application Vertical During Assembly 21

Preparation of Joint Casting Material 22

Junction Resistance Test Report 24

Line Insulation Resistance Test Report 25

The busbar system's successful operation depends on correct handling, installation,

Joint Area General Information

Pre-Cast Controlling of Juncture Area:

Strapping type ropes should

Short modules can be handled by a single rope,

Figure 1 Figure 2 Figure 3

FIGURE 1 - EDGEWISE APPLICATION FIGURE 5 - CROSSING UNDER A BEAM ON

FIGURE 2 - EDGEWISE APPLICATION FIGURE 6 - SAMPLE WALL CROSSING

EXTERNAL FIRE BARRIER

Primarily on the installation phase;

FIGURE 3 - FLATWISE APPLICATION FIGURE 7 - STANDARD WALL CROSSING

Primarily on the installation phase;

FIGURE 4 - CROSSING UNDER A BEAM ON EDGEWISE APPLICATION

The joint should be not come across to Beams.

PE L3 L2 L1 N The dimensions given above are minimum values.

CR-UT HANGER SET FOR FLATWISE APPLICATION (NON-STANDARD APPLICATION)

CRA - Al CRC - Cu Conductor Order

BRA 12-05 Threaded Rod (M10) 500 5000037

Washer M10 Steel Nut - 1000522

Please call us for non-standard dimensions. M12 Washer - 1000505

Description L Order Code

IDY 300 300 3008242

IDD 300 300 3008314

IDT Support Fitting - 3008279

Please call us for non-standard dimensions.

Description T L Order Code

UPY 300 4 300 3004487

Please call us for non-standard dimensions.

Nut Set Socket Set Wrench, Screwdriver Lifting Device

Megger Device Dielectric Test Device 5 kV DC Paint Brush Scaffold

Mixer Putty knife Protective Clothes, Drill

Preparation of Cast Resin Mixture

FILLER RESIN (A) HARDENER (B)

Junction Resistance Test

Line Insulation Resistance Test

< 5°C STOP

Customer: Date: ........./ ......../ ............

Customer: Date: ........./ ......../ ............

N - L2 = .............................................. / .............................................. MΩ Standard Conductor

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

2014/30/EU “Electromagnetic Compatibility (EMC) Directive”

2011/65/EU “Restriction of the use of certain hazardous substances (RoHS)”