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Lightweight Section Insulator Sicat 8WL5545 for Overhead Contact Line Systems
Operating Instructions Version 3.2.2
Siemens AG Industry Sector Mobility Division Turnkey Systems Copyright Siemens AG 2002 - 2008. All rights reserved.
The group Transportation Systems of the Siemens AG has established and maintains for the scope Project Planning, Aquisition, Engineering, Procurement, Production, Assembly, Commissioning and Service of Products, Systems and Services in the fields of Rail Automation, Electrification, Locomotives, Trains, Mass Transit, Bogies, Turnkey Systems and Integrated Services an integrated quality, safety, health and environmental management system in conformity with the standards: ISO 9001:2000 ISO 14001:2004 OHSAS 18001:1999 Certification was issued by the DNV Zertifizierung und Umweltgutachter GmbH and confirmed by regular audits.
If you require additional copies of these operating instructions, please order from the responsible Siemens sales office, stating the title and the following document number: A6Z08110337684
Issued by: Siemens AG Industry Sector Mobility Division Turnkey Systems P.O. Box 32 40 91050 Erlangen Germany E-Mail: techcom.el.mobility@siemens.com Subject to change without notice! Siemens AG 2002 - 2008
NOTE
The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. Sicat is a registered trademark of Siemens. The other names appearing in this documentation may be trade names, the use of which by third parties for their own purposes may infringe the rights of the respective owners.
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Table of contents
1 2 2.1 2.2 2.3 2.4 2.5 3 4 4.1 4.2 4.3 4.3.1 4.3.2 5 5.1 5.2 5.3 6 6.1 6.1.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tests and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport conditions ................................................ Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clamping the contact wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of suspension ............................................ ................................. Assemble lightweight section insulators 5 6 6 7 7 8 8 9 10 10 11 11 11 14 15 15 15 15 16 16 17 20 21 22 22 25 27
Lightweight section insulator with one insulating rod . . . . . . . . . . . . . . . . . . . . . . . . Lightweight section insulator with two insulating rods . . . . . . . . . . . . . . . . . . . . . . . Adjust lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7 7.1 7.2 8 8.1 8.2 8.2.1 8.2.2 8.3 8.3.1 8.3.2 8.3.3 9 9.1 9.1.1 9.1.2 9.1.3 9.2 9.3 9.4 9.5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly ...................................................... Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection ........................................................ Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotate insulating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the insulating rod ........................................... ..................................... Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replace runners with arcing horns Replace insulating rods on the lightweight section insulator . . . . . . . . . . . . . . . . . . Replace the insulating rod in the catenary wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lightweight section insulator for nominal voltage up to 3 kV DC . . . . . . . . . . . . . . . Lightweight section insulator for nominal voltage 15 kV AC . . . . . . . . . . . . . . . . . . Lightweight section insulator for nominal voltage 25 kV AC . . . . . . . . . . . . . . . . . . Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts ....................................................... Accessories and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 31 31 32 32 32 33 34 34 34 36 36 37 37 37 37 38 38 38 39 39
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General
General
These operating instructions are valid for the standard version of the product Sicat 8WL5545 as from model year 2006. The operating instructions (according to IEC 62079:2001) are intended to make any personnel familiar with the product.
WARNING
Death, serious physical injury and damage to property can occur. During the operation of electrical equipment, certain parts of the equipment are inevitably energised at dangerous electrical voltages. Observe the safety regulations and warnings included in these operating instructions and on the product. Read these operating instructions completely before installing this product. Keep these operating instructions ready to hand so that you can refer to important information at all times. A correct and safe operation of the product can be guaranteed only after suitable transport, proper storage, erection, assembly, commissioning and careful maintenance.
NOTE
In the interests of clarity, these operating instructions do not contain all detailed information for all types of the product and cannot take all conceivable conditions for the erection, operation and maintenance into account. If you require further information, or if special problems arise, that have not been referred to sufficiently in the operating instructions, the necessary information can be requested through the local Siemens branch office. We also draw attention to the fact that the contents of these operating instructions do not represent a part of an earlier or existing agreement, warranty or legal relationship, nor do they alter the such. All obligations on behalf of Siemens are based upon the respective purchase contract, which also contains the complete and exclusively applicable warranty conditions. These contractual warranty conditions are neither extended nor limited by the explanations given in these operating instructions.
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Safety
Safety
SIGNAL WORD
Symbol
Meaning in the context of these operating instructions and the warning notices on the products themselves, means that death or serious physical injury will occur, if the corresponding safety measures are not obeyed. in the context of these operating instructions and the warning notices on the products themselves, means that death or serious physical injury can occur, if the corresponding safety measures are not obeyed. in the context of these operating instructions and the warning notices on the products themselves, means that a light physical injury or damage to property can occur, if the corresponding safety measures are not obeyed. in the context of these operating instructions is an important information related to the product or to the respective section of the documentation, to which special attention is to be drawn.
Warning
Attention
Note
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Safety
WARNING
Use of the product for purposes that are not intended can cause death, serious physical injury, considerable damage to property and environmental pollution.
Use the product only for its intended purpose (see also section "Purpose and use" on page 9). The use complies with the intended purpose if: the product is operated in accordance with the agreed terms of delivery and the stated technical specification, and any supplied devices and special tools are used exclusively for the intended purpose and in accordance with the appropriate instructions in these operating instructions.
All other methods of use are forbidden unless explicit written agreement has been issued by Siemens AG.
In addition, all persons performing the installation, commissioning, operation and maintenance of the product must also possess qualifications and experience in the following basic skills: installation methods, working in accordance with, and on the basis of drawings, working in accordance with the operating instructions, accident prevention and safety regulations, commissioning methods and commissioning procedures, first aid.
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Safety
Use personal protective equipment as specified by national accident prevention regulations (in Germany BGV A 1 or BGR 189-199).
DANGER
Risk of fatal injury through high voltage at the electrical system. Observe the warnings in these operating instructions and on the product.
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Lightweight section insulators are used not only to divide the overhead contact lines into different switching and feeder sections but also to isolate these sections from each other electrically. The lightweight section insulators can be employed for electrical separation of the overhead contact line between the main tracks as well as between the main tracks and sidings, for sectionalizing and for phase or system isolation gaps in combination with earthed and neutral overhead contact line sections. Thanks to their excellent arc-extinguishing properties, lightweight section insulators can also be installed wherever high voltage differentials exist between switchgear. The Sicat 8WL5545 series lightweight section insulators are used in mass transit and mainline systems. Depending on the pantographs and overhead line types used, they can be passed by electric-powered trains running at a maximum speed of up to 200 km/h.
ATTENTION
Install the lightweight section insulator for mass transit (variant 8WL5545-7A/-8A) only in a conventional catenary overhead line system. Suspension with two triangular droppers is necessary for lightweight section insulators. The lightweight section insulator is primarily intended for installation on straight sections of track as otherwise it could be subject to increased wear.
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Design
Design
4.1 General
The lightweight section insulator consists of the following main components:
3a
3b
Lightweight section insulator with one insulating rod and for one contact wire
3a
3b
Lightweight section insulator with two insulating rods and for two contact wires 1 2 contact wire dead-end clamp suspension strap 3a 3b runner with arcing horn (short) runner with arcing horn (long) 4 5 insulating rod rail web*
* There are no rail webs at the variants 8WL5545-7A , 8WL5545-8A and 8WL5545-8AC
The insulating rods are arranged at the level of the contact wire so that no bending moments occur on the lightweight section insulator. The pantograph can slide over the insulating rods at those points where the air clearances are. Spare parts and accessories can be exchanged quickly and easily as a result of the modular design and the attachment method used.
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Design
Electrical test:
4.3 Variants
4.3.1 Lightweight section insulator
Lightweight section insulators are available in the below-mentioned designs (see table). They vary in: the number of insulating rods and the resulting maximum operating load the length of insulating rods, the corresponding creepage distance and the resulting permitted nominal voltage the use of rail webs the number and distance of contact wires to be connected
Number of Nominal voltage contact wires to up to 3 kV DC be connected 1 1 1 1 2 2 8WL5545-7A 8WL5545-8A 8WL5545-8AC Nominal voltage 15 kV AC 8WL5545-0A 8WL5545-1A Nominal voltage 25 kV AC 8WL5545-3A 8WL5545-4A 8WL5545-4AC 8WL5545-4AD 8WL5545-2A
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Design
4.3.1.1
L2
H L1
NOTE
The lightweight section insulators 8WL5545-1A, 8WL5545-2A, 8WL5545-4A, 8WL5545-4AC and 8WL5545-4AD have rail webs (see Figure "Lightweight section insulator with one insulating rod and for one contact wire" on page 10).
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Design
4.3.1.2
L2
L1
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Design
There are two suspension designs for corresponding nominal voltages (see table):
Type of suspension Order number Nominal voltage L [mm] 3 kV DC 15 kV AC 25 kV AC 25 kV AC 1600 1600 2000 2200 A [mm] ~ 700 ~ 1010 ~ 1450 ~ 1650 K [mm] 1350 1350 1750 1950 Suspension with catenary wire insulation - for lightweight section insulator up to 3 kV DC 8WL5545-5A - for lightweight section insulator 15 kV AC Suspension with catenary wire insulation - for lightweight section insulator 25 kV AC - for lightweight section insulator 25 kV AC 8WL5545-6A 8WL5545-6AD
L K
20
25.6
14
Suspension 7 8 9 11 12 14 L A K end fitting insulating rod of the suspension turnbuckle dead-end clamp dropper wire rod pulley length of insulating rod distance between the dropper wires min. creepage distance
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The means of transport to and at the installation site must be suited to the transportation with respect to construction and load capacity. The notices on the packing regarding weight, lifting and transport are to be observed.
5.2 Packing
The lightweight section insulators are delivered in a standard packaging.
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Installation
Installation
WARNING
In order for the lightweight section insulator to be operated safely, it must be mounted and commissioned properly by qualified personnel in accordance with the warnings in these operating instructions. Failure to comply can result in death, serious injury or considerable damage to property.
ATTENTION
Install the lightweight section insulator for mass transit (variant 8WL5545-7A/8A) only in a conventional catenary overhead line system. Suspension with two triangular droppers is necessary for lightweight section insulators. The lightweight section insulator is primarily intended for installation on straight sections of track as otherwise it could be subject to increased wear.
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport. Do not lift or carry one-sidedly or by means of the insulating rod. Carry the lightweight section insulator holding both suspension brackets at the same time.
Please observe the following before installing the section insulator: Wherever possible, the section insulator should be installed in a location that is in a straight span between one third and half of the tension length in order to ensure for uniform uplift. The contact wire and catenary wire must be perpendicular to each other at the installation location. Contact wire and catenary wire must lie in the mid-perpendicular to the plane of top of rails (tolerance: 50 mm). NOTE
To facilitate transport the lightweight section insulator variants 8WL5545-0A/-1A/-2A/-3A/-4A are delivered without the runners and rail webs fitted. These come packed together with the insulators and have to be fitted prior to installation and use.
NOTE
If you use the lightweight section insulator for an unworn AC-100 contact wire, the clamps for outer attachment of the runners must be fixed in the round hole at the end of the runner. For other contact wires, the clamp attachment for fixing the outer runners is provided at the elongated hole.
In order to clamp contact wires with nominal cross-sections greater than 120mm2, the factory-prepared mounting
position of the contact wire dead-end clamps (1) must be changed on the straps (6) (see Section 6.1.1 "Clamping the contact wires" on page 17).
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Installation
contact wire 1a 6
mounting height 4
Contact wires with nominal cross-section up to 120 mm To permit clamping of contact wires with nominal cross-sections of up to 120 mm, the clamping jaws of the contact wire dead-end clamp (1a) are mounted in the factory in the outer four location holes (see Figure "Position of the clamping jaw for contact wires with nominal cross-sections of up to 120 mm").
1a
Position of the clamping jaw for contact wires with nominal cross-sections of up to 120 mm 1a clamping jaw 6 strap
1,5
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Installation
Contact wires with nominal cross-section up to 120 mm In order to clamp contact wires with nominal cross-sections greater than 120 mm, position the clamping jaws of the contact wire dead-end clamp (1a) one hole closer to the inside (see Figure "Position of the clamping jaw for contact wires with nominal cross-sections greater than 120 mm").
1a
Position of the clamping jaw for contact wires with nominal cross-sections greater than 120 mm 1a clamping jaw 6 strap
1. 2.
Remove packing. Screw a short and a long runner to the clamp for the outer attachment of the runners and to the straps. The links for height adjustment are located on the outer sides of the runners. The bolts of the links point inward and can be slide in the elongated hole of the runners.
3. 4.
Screw tight the rail webs between the runners at the variants 8WL5545-0A/-1A/-2A/-3A/-4A/ -4AC and -4AD. Check the adjustment at the clamps (6a) for outer attachment of the runners.
1,5
6a 10
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Installation
5. 6. 7. 8. 9.
Fix the clamps for outer attachment of the runners in the round hole for unworn contact wire AC-100 or in the elongated hole for all other contact wire types. Establish and note the track superelevation or the gradient of the rail head contact plane at the installation location of the lightweight section insulator. Check whether the contact wire and the catenary wire lie in the mid-perpendicular to the rail head contact plane. If not, correct the dimension (tolerance: 50 mm). Remove any existing kinks and twists in the contact wire. Measure and note the contact wire height at the installation location of the lightweight section insulator, starting from the installation platform or the mobile ladder.
10. Raise the contact wire in the installation area using the spring balance. You can find the lifting force corresponding to the running speed in the following table.
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Installation
11. Determine and note the contact wire height with the lifting force according to the Table "Orientation values for contact wire lift" on page 19. The lower edges of the runners of the lightweight section insulators should be at this height after installation. If you are using an installation platform, use it as the reference point. The installation platform must then not be raised or lowered until the lightweight section insulator has been installed.
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hcontact wire
hsection insulator
Installation
1. 2.
Mount the dead-end clamps (11) suitable for the messenger wire on the end fittings (7) of the insulating rod. Calculate the length of the catenary wire section to be cut out.
ATTENTION
Bending the insulating rod in order to install it in the catenary wire will cause damage to the rod. Release the tension in the catenary wire in the installation area only far enough to enable the insulating rod to be installed in the catenary wire without having to bend it in the process. Avoid causing any distortion in the catenary system.
3.
Install the tensioning device and release the tension in the catenary wire in the installation area until the part of the messenger that is to be cut out starts to sag slightly. The catenary system must not be distorted in the process.
4. 5.
Cut the catenary wire. Assemble the suspension to the catenary wire insulation. Make sure that the catenary wire does not become twisted. There must be no torsion forces acting on the insulating rod in the catenary wire.
6. 7.
Check the connections between the insulating rod and the catenary wire. Carefully load the catenary wire with the weight of the installed suspension and remove the tensioning device.
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Installation
ATTENTION
Bending the insulating rod of the section insulator in order to install it in the contact wire will cause damage to the rod. Release the tension in the contact wire in the installation area only far enough to enable the section insulator to be installed in the contact wire without having to bend the insulating rod in the process. Avoid causing any distortion in the catenary system.
1.
Install the tensioning device with contact wire stringing grips and sling and release the tension in the contact wire until it starts to curve upwards in the installation area.
2.
Mark the interfaces of the contact wire on the contact wire. The lightweight section insulator must be installed symmetrically under the suspension. Look in the table in Section 4.3.1.2 "Lightweight section insulator with one insulating rod" on page 13 for the length of contact wire to be cut out (L2). The contact wire must protrude inward beyond the inner edges of the two dead-end clamps by approximately 120 mm.
0 12
m m
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Installation
3.
4. 5. 6.
Place the lightweight section insulator on the contact wire symmetrically to the insulating rod in the catenary wire. Hook the ring hooks of the turnbuckles of the suspension into the suspension straps of the lightweight section insulator. Install both contact wire dead-end clamps of the lightweight section insulator on the contact wire. Ensure that you tighten the M10 screws of the contact wire dead-end clamps from outside inwards using two double-ended ring spanners.
7.
Tighten the screws two times with a suitable torque wrench, allowing at least one minute to pass after each time. The tightening torque is MA = 60 Nm.
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Installation
8.
Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening torque is MA = 43 Nm.
6a
9.
Retighten the screws on the contact wire dead-end clamps (1) three times to a torque of 60 Nm, allowing at least one minute to pass after each time.
10. Retighten the screws on the clamps (6a) for outer attachment of the runners once more to a torque of 43 Nm.
0 12
m m
11. Lock the nuts on the clamps (6a) for outer attachment of the runners. 12. Bend the end section of the contact wire (120 mm) few millimetres upwards. 13. Remove the tensioning device and contact wire stringing grips. The lightweight section insulator is then loaded with the contact wire tensile force. 14. Remove any existing kinks and twists in the contact wire. 15. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section insulator" on page 27.
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Installation
4. 5.
Tighten the screws two times with a suitable torque wrench, allowing at least one minute to pass after each time. The tightening torque is MA = 60 Nm. Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening torque is MA = 43 Nm.
6a
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Installation
6. 7.
Retighten the screws on the contact wire dead-end clamps three times to a torque of 60 Nm, allowing at least one minute to pass after each time. Retighten the screws on the clamps (6a) for outer attachment of the runners once more to a torque of 43 Nm.
8. 9.
Lock the nuts on the clamps (6a) for outer attachment of the runners. Cut the central contact wire section off in such a manner that approximately 120 mm of the contact wire remains behind the contact wire dead-end clamp.
0 12
m m
10. Bend the end section of the contact wire a few millimetres upwards. 11. Remove any existing kinks and twists in the contact wire. 12. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section insulator" on page 27.
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Installation
Adjust the height of the lightweight section insulator as measured in Section 6.1 "Preparatory work" on page 16, by adjusting the suspension as follows: 1. Adjust the suspension roughly at the Primodur clamps. Release the nuts at the Primodur clamps, move the wire and tighten the nuts.
2. 3.
Carry out the fine adjustment of the suspension at the turnbuckles. Set the position of the runner lower edge of the runner transversely to the track, parallel to the track superelevation established in Section 6.1 "Preparatory work" on page 16 or the gradient of the rail head contact plane.
The height of the outer runner ends is permanently set for unworn standard contact wire (AC100) by the way the clamps (6a) are attached in the round hole. For worn or other contact wires, adjust the height of the outer runner ends by using the elongated holes provided. For
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Installation
this purpose, the clamps (6a) for outer attachment of the runners must be repositioned in the elongated holes.
6a
round hole
elongated hole
NOTE
The lower edges of the runners should be 4 mm below the lower edge of the end fitting of the insulating rod (see Figure "Checking the adjustment "A"" on page 29). The transitions from the contact wire to the runners and from the runners to the insulating rod should not show height differences. The pantograph must be transferred smoothly to the runners and must not nudge against the runner ends. At the same time, each contact strip of the pantograph must make constant contact with at least one runner.
4.
Adjust the height of the runners parallel to the track: Use a pencil to mark the position of the link on the left and on the right. Loosen the screws on the links and move the links to one side. (Moving the link laterally by one millimetre corresponds to 0.5 mm adjustment in the height of the lower edge of the runner).
5. 6.
Tighten the screws on the links slightly. Check the position of the runners transversely to the track so that they are parallel with the plane of top of rails.
7.
Place a spirit level across the bottom of the runners in the area of the clamping plates. Check the adjustment "A" (see Figure "Checking the adjustment "A"" on page 29). The adjustment "A" is 4 mm for all types. In case of a deviation, reset this adjustment accordingly.
8.
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Installation
detail X
13a
14
15
Checking the adjustment "A" 3 4 4a A B runner insulating rod end fitting of the insulating rod 13a 14 15 clamping plate of the end fitting Measuring tool spirit level
Adjustment between bottom of clamping plate (13a) and bottom of runners (B) Bearing surface for measuring device after spirit level has been placed across bottom of runners
9.
Test the passage characteristics of the lightweight section insulator by passing a pantograph over the insulator (if present on the multiple purpose vehicle). The pantograph must be transferred smoothly to the runners. The pantograph must not strike the inner or the outer ends of the runners.
10. Tighten all screws of the links with a torque spanner with a torque of MA = 43 Nm. 11. Tighten the counter nuts to secure the turnbuckles.
A = 4 mm
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Installation
13. Adjust the droppers in front of and behind the lightweight section insulators so that they are tight, but do not change the height of the lightweight section insulator.
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Disassembly
Disassembly
7.1 Disassembly
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport. Do not lift or carry onesidedly or by means of the insulating rod. Carry the lightweight section insulator holding at the suspension straps at the same time.
1.
Release the tension in the contact wire, and thus in the section insulator as well, with the aid of a tensioning device with contact wire stringing grips and sling (see Section 6.4.1 "Lightweight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the catenary wire and thus the insulating rod of the suspension in the installation area only far enough to enable the connections to the catenary wire to be undone, the insulating rod removed and replaced with a new one without having to bend the new insulating rod in the process. Avoid causing any distortion in the catenary system.
2. 3. 4. 5. 6. 7. 8. 9.
Disassemble the suspension of the suspension straps of the lightweight section insulator. Disassemble the lightweight section insulator. Assemble a new lightweight section insulator or place a section of contact wire with contact wire splices into the space. Remove the tensioning device and contact wire stringing grips. If a new lightweight section insulator is not to be assembled, release the tension in the catenary wire with the tensioning device, catenary wire stringing grips and sling. Disassemble the suspension. Insert a new piece of catenary wire. Remove the tensioning device and catenary wire stringing grips.
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Maintenance
Maintenance
WARNING
Death or severe bodily injury can occur due to high electric voltage. De-energize the overhead line system before performing maintenance work or safeguard the maintenance location or the overhead line system in accordance with the regulations.
8.1 Inspection
Inspect the lightweight section insulator after every short-circuit in the relevant area. Inspect the lightweight section insulator for possible damage after short-circuits caused by pantograph passes into earthed sections. If evidence of overheating is visible, replace the suspension wires. The contact forces of passing pantographs are higher in DC systems than in AC systems. Higher runner wear must therefore be expected.
Type of system Inspection interval after commissioning AC system DC system yearly or after about 100.000 pantograph passages
Evaluation - Erosion at the arcing horns - Remaining cross-sectional area of the runners in the areas of greatest wear (see Figure "Areas of greatest runner wear" on page 35) Use a torque wrench to check the bolted connections (tightening torque MA = 60 Nm). Dirt deposits impair the insulating effect. Clean the insulating rod during maintenance work. If the wear zone has been used up, rotate the insulating rod as required or replace if necessary (see Figure "Insulating rod wear" on page 33). Check the connections between the insulating rod and the catenary wire
Suspension
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Maintenance
ATTENTION
The insulating rod will be damaged if you release it at only one end and then rotate it. Observe the following handling instructions. Rotate the insulating rod simultaneously at both ends.
The insulating rods can be rotated up to three times, which ensures even wear and maximum service life. The rotation must be performed when the wear is 2.5 3.5 mm of the nominal diameter (see Figure "Insulating rod wear" on page 33. The diameter of an insulating rod is 20 mm.
wear zone dimension in mm
17.5 ...16.5
17.5 ...16.5
15...13
20
15...13
turned 180
turned 90
turned 180
replace
13a
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Maintenance
1.
Install the tensioning device with contact wire stringing grips and sling and release the tension in the contact wire and thus in the section insulator in the installation area (see Section 6.4.1 "Lightweight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the contact wire and thus in the section insulator in the installation area only far enough to enable the insulating rod to be disconnected from the section insulator, rotated and tightly secured again without having to bend the insulating rod in the process. Avoid causing any distortion in the catenary system.
2. 3. 4. 5.
Loosen the screws at both clamping plates (see Figure "Rotate insulating rod" on page 33), in which the insulating rod is fixed. Rotate the insulating rod simultaneously at the ends into the desired position. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm. Replace the insulating rods when the wear of material is roughly 3 mm on all sides.
ATTENTION
Only original spare parts supplied by Siemens AG may be used for maintenance work. In the event of a repair, contact your Siemens agency.
ATTENTION
Damage can be caused to the lightweight section insulator by incorrect assembly. Take note of the diagonal arrangement of the runners in asymmetrical lightweight section insulators.
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Maintenance
Exchange the runners if due to arcing the dimension between lower edge of the runner and top edge of the arcing horn is less than 100 mm or the remaining cross-section of the runners in the areas of greatest wear has been worn down to 3 mm and therefore the necessary stability is no longer ensured (see Figure "Areas of greatest runner wear" on page 35).
detail A
100
detail B
wear zone
dimensions in mm
1. 2. 3. 4. 5.
Remove the screws and the links for the height adjustment of the runners. Remove the runners. Fix the new runners. Repeat the handling instructions 1 to 3 for the other three runners, if necessary. Adjust the runners or the lightweight section insulator as described in Section 6.5 "Adjust lightweight section insulator" on page 27.
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Maintenance
1.
Install the tensioning device with contact wire stringing grips and sling and release the tension in the contact wire and thus in the section insulator in the installation area (see Section 6.4.1 "Lightweight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the contact wire and thus in the section insulator in the installation area only far enough to enable the insulating rod to be disconnected from the section insulator and removed and a new one to be installed and tightly secured again without having to bend the new insulating rod in the process. Avoid causing any distortion in the catenary system.
2. 3. 4. 5.
Loosen the screws at the ends of the clamping plates. Remove the insulating rod. Insert the new insulating rod. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm.
1.
Install the tensioning device with contact wire stringing grips and sling and release the tension in the catenary wire and thus in the suspension in the installation area (see Section 6.4.1 "Lightweight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the catenary wire and thus the insulating rod of the suspension in the installation area only far enough to enable the connections to the catenary wire to be undone, the insulating rod removed and replaced with a new one without having to bend the new insulating rod in the process. Avoid causing any distortion in the catenary system.
2. 3. 4. 5. 6. 7.
Remove the dropper wires from the insulating rod. Disconnect the insulating rod from the wedge-type dead-end clamps of the catenary wire. Fix the dropper wires to the new insulating rod. Connect the insulating rod to the wedge-type dead-end clamps of the catenary wire. Check the connections between the insulating rod and the catenary wire. Remove the tensioning device.
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Technical data
Technical data
AC/BC-80 to 150, Cu-ETP AC/BC-80 to 150, CuAg0.1 AC/BC-80 to 120, CuMg0.5 Ri161, Cu-ETP (British Standard 23) CTHA-85/-120 (China Standard)
AC/BC-80 to 150, Cu-ETP AC/BC-80 to 150, CuAg0.1 AC/BC-80 to 120, CuMg0.5 Ri161, Cu-ETP (British Standard 23) CTHA-85/-120 (China Standard)
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Technical data
AC/BC-80 bis 150, Cu-ETP AC/BC-80 bis 150, CuAg0.1 AC/BC-80 bis 120, CuMg0.5 Ri161, Cu-ETP (British Standard 23) CTHA-85/-120 (China)
9.3 Materials
Part Clamping fittings Runners with arcing horns Insulating rods (section insulator) Insulating rods (suspension) End fittings (suspension) Turnbuckles Rod pulley Dropper wire 16f Material CuNiSi (Copper-Nickel wrought alloy) Copper GRP (Glass-fiber reinforced plastic), PTFE GRP (Glass-fiber reinforced plastic), silicone stlSt (Stainless steel) stlSt (Stainless steel) Polyamide, CuSn (Tin bronze) BzII (Bronze, strength grade II)
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Technical data
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Siemens AG Industry Sector Mobility Division Turnkey Systems P.O.Box 32 40 91050 Erlangen Germany electrification.mobility@siemens.com www.siemens.com/mobility/ electrification Sicat 8WL5545 Operating Instructions / Version 3.2.2 A6Z08110337684 / Status: 2008-11-20 Subject to change without prior notice!