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Siemens AGIndustry SectorMobility DivisionTurnkey Systems

Copyright © Siemens AG 2002 - 2008. All rights reserved.

Lightweight Section Insulator Sicat 8WL5545for Overhead Contact Line Systems

Operating Instructions Version 3.2.2

2 / 40 Sicat 8WL5545 / Operating Instructions / Version 3.2.2 / A6Z08110337684

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 9001:2000ISO 14001:2004OHSAS 18001:1999Certification 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 AGIndustry SectorMobility DivisionTurnkey SystemsP.O. Box 32 4091050 ErlangenGermanyE-Mail: [email protected] to change without notice!

© Siemens AG 2002 - 2008

NOTEThe reproduction, transmission or use of this document or its contents is not permitted without express written au-thority. 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.

Sicat 8WL5545 / Operating Instructions / Version 3.2.2 / A6Z08110337684 3 / 40

Table of contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1 Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.5 Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.2 Tests and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3.1 Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3.2 Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155.1 Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.3 Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6.1.1 Clamping the contact wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.2 Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.3 Installation of suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.4 Assemble lightweight section insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.4.1 Lightweight section insulator with one insulating rod . . . . . . . . . . . . . . . . . . . . . . . . 22

6.4.2 Lightweight section insulator with two insulating rods . . . . . . . . . . . . . . . . . . . . . . . 25

6.5 Adjust lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27


7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.2 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.2.1 Rotate insulating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.2.2 Cleaning the insulating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.3 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.3.1 Replace runners with arcing horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.3.2 Replace insulating rods on the lightweight section insulator . . . . . . . . . . . . . . . . . . 36

8.3.3 Replace the insulating rod in the catenary wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379.1 Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9.1.1 Lightweight section insulator for nominal voltage up to 3 kV DC . . . . . . . . . . . . . . . 37

9.1.2 Lightweight section insulator for nominal voltage 15 kV AC . . . . . . . . . . . . . . . . . . 37

9.1.3 Lightweight section insulator for nominal voltage 25 kV AC . . . . . . . . . . . . . . . . . . 38

9.2 Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.5 Accessories and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General


1 GeneralThese 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.

WARNINGDeath, 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.

NOTEIn 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 oper-ating 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.

Safety


2 Safety

2.1 Description of the warning notices

These operating instructions contain warnings based on signal words in order to indicate the degrees of danger.

Such warning notices can also be utilised in the form of sign boards or as stickers attached to the product.

Symbol SIGNAL WORDMeaning ...

Symbol Signal word Meaning

Danger 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.

Warning 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.

Attention 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.

Note 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.

Safety


2.2 Intended use

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 tech-nical 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.

2.3 Personnel qualification

A person is qualified if he/she is familiarized with:

• the transport,• the installation,• the construction,• the operation,• the maintenance of the product and• the associated dangers.

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.

Please refer to national regulations (e. g. BGV A 3 in Germany, EN 50110 in Europe).

WARNINGUse of the product for purposes that are not intended can cause death, serious physical injury, considerable damage to property and environmental pollution.

Safety


2.4 Safety requirements

Pay attention to the generally applicable and legally binding safety regulations.

Instruct the personnel regularly on the currently applicable rules and regulations, the generally applicable accident prevention regulations and legally binding safety instructions.

Irrespective of these, the following five safety rules according EN 50110-1:2004 apply:

Use personal protective equipment as specified by national accident prevention regulations (in Germany BGV A 1 or BGR 189-199).

2.5 Sources of danger

If the specified requirements and conditions have not been obeyed or the safety instruction have not been followed, then dangers are threatened by:

NOTEBefore carrying out any work, do the following:• Isolate the plant• Secure against being switched on• Make sure there is no residual voltage in the plant• Earth and short-circuit the plant• Cover or safeguard live parts

DANGERRisk of fatal injury through high voltage at the electrical system.Observe the warnings in these operating instructions and on the product.

Purpose and use


3 Purpose and useLightweight 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 section-alizing 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.

ATTENTIONInstall 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.

Design


4 Design

4.1 General

The lightweight section insulator consists of the following main components:

Lightweight section insulator with one insulating rod and for one contact wire

Lightweight section insulator with two insulating rods and for two contact wires

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.

1 contact wire dead-end clamp 3a runner with arcing horn (short) 4 insulating rod2 suspension strap 3b runner with arcing horn (long) 5 rail web*

* There are no rail webs at the variants 8WL5545-7A , 8WL5545-8A and 8WL5545-8AC

1 2 3a 4 53b 12

1 2 3a 4 3b 2 1

Design


4.2 Tests and standards

The tests of the lightweight section insulators have been carried out in accordance with the following standards:

Mechanical test:• DIN VDE 0216:1986• EN 50119:2001

Electrical test:• IEC 61109:1992• IEC 60071-1:1993• IEC 60383-1:1993• IEC 60060-1:1989

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 insulating rods

Max. perm. operating load

Number of contact wires to be connected

Nominal voltage up to 3 kV DC

Nominal voltage15 kV AC

Nominal voltage 25 kV AC

1 15 kN 1 – 8WL5545-0A 8WL5545-3A

2 30 kN 1 8WL5545-7A 8WL5545-1A 8WL5545-4A

2 30 kN 1 – – 8WL5545-4AC

2 30 kN 1 – – 8WL5545-4AD

2 30 kN 2 8WL5545-8A – 8WL5545-2A

2 30 kN 2 8WL5545-8AC – –

Design


4.3.1.1 Lightweight section insulator with two insulating rods

Lightweight section insulator for two contact wires

Dimensions of the lightweight section insulator

Variant Sicat 8WL5545 up to 3 kV DC 15 kV AC 25 kV AC

Type -7A -8A -8AC -1A -4A -4AC -4AD -2AL1 [mm] 1725 1725 1725 2050 2490 2490 2688 2490

L2 [mm] 780 780 780 1170 1610 1610 1810 1610

L3 [mm] 700 700 700 1010 1450 1450 1654 1450

B [mm] 340 362 375 450 450 539 539 472

H [mm] 208 208 208 238 238 242 242 238

C [mm] – 28 40 – – – – 28

NOTEThe 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).

L3

H

B

L1

C

L2

Design


4.3.1.2 Lightweight section insulator with one insulating rod

Lightweight section insulator for one contact wire

Dimensions of the lightweight section insulator

Variant 8WL5545-0A 8WL5545-3A15 kV AC 25 kV AC

L1 [mm] 2050 2490

L2 [mm] 1170 1610

L3 [mm] 1010 1450

B [mm] 450 450

H [mm] 238 238H

L3

L2

B

L1

Design


4.4 Suspension (Accessories)

There are two suspension designs for corresponding nominal voltages (see table):

Suspension

7 end fitting 8 insulating rod of the suspension9 turnbuckle11 dead-end clamp12 dropper wire14 rod pulleyL length of insulating rodA distance between the dropper wiresK min. creepage distance

NOTEThe suspension is not included in the scope of delivery of the lightweight section insulator and has to be ordered separately. The dead-end clamps (11) are not included in the scope of delivery of the suspension and have to be ordered sepa-rately.

Type of suspension Order number Nominal voltage L [mm] A [mm] K [mm]Suspension with catenary wire insulation- for lightweight section insulator up to 3 kV DC- for lightweight section insulator 15 kV AC

8WL5545-5A 3 kV DC15 kV AC

16001600

~ 700~ 1010

13501350

Suspension with catenary wire insulation- for lightweight section insulator 25 kV AC- for lightweight section insulator 25 kV AC

8WL5545-6A8WL5545-6AD

25 kV AC25 kV AC

20002200

~ 1450~ 1650

17501950

A

20

2719

LK

78 11m

in. 7

00m

ax. 1

940

132

9

12

14

ø25.

6

centre of contact wire

Transport and storage


5 Transport and storage

5.1 Transport conditions

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.

5.3 Checks on receipt

The shipment must be checked immediately on receipt for damage and for completeness based on the delivery notes.

NOTEThe 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.

NOTEIf the consignment is damaged, the scope and cause of the damage is to be established, documented in writing and reported to the supplier without delay. The forwarding agent is to be enlisted to record the facts if transport damage has occurred. A written record is essential for damage claims.

Installation


6 Installation

6.1 Preparatory work

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).

WARNINGIn 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.

ATTENTIONInstall 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.

NOTEThe 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.

NOTETo 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 instal-lation and use.

NOTEIf 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).

Installation


6.1.1 Clamping the contact wires

Contact wires with different cross-sections can be clamped together with the clamping jaws (1a) of the contact wire dead-end clamp. Since the the position and diameter of the insulating rod (4) or rods in the section insulator are always the same, the mounting height between the contact wire to be clamped and the insulating rod or rods varies according to the cross-section in question (see Fig. "Mounting height" on page 13). To enable the deviation in the mounting height between con-tact wire and insulating rod to be optimized the clamping jaws (1a) are to be mounted on the straps (6) adjustably and according to each contact wire cross-section.

Mounting height

1a clamping jaw4 insulating rod6 strap

Contact wires with nominal cross-section up to 120 mm²To permit clamping of contact wires with nominal cross-sections of up to 120 mm², 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 mm²").

Position of the clamping jaw for contact wires with nominal cross-sections of up to 120 mm²

1a clamping jaw6 strap

contact wire mounting height41a 6

61a

1,5°

Installation


Contact wires with nominal cross-section up to 120 mm²In order to clamp contact wires with nominal cross-sections greater than 120 mm², 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 mm²").

Position of the clamping jaw for contact wires with nominal cross-sections greater than 120 mm²

1a clamping jaw6 strap

1. Remove packing.

2. 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. Screw tight the rail webs between the runners at the variants 8WL5545-0A/-1A/-2A/-3A/-4A/-4AC and -4AD.

4. Check the adjustment at the clamps (6a) for outer attachment of the runners.

1a 61,

5°

6a

10

Installation


5. 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.

6. Establish and note the track superelevation or the gradient of the rail head contact plane at the installation location of the lightweight section insulator.

7. 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).

8. Remove any existing kinks and twists in the contact wire.

9. 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.

Orientation values for contact wire lift

Maximum running speed [km/h] Lifting force for single contact wires [N] Joint lifting force for double contact wires [ N]

20 80 120

100 100 140

160 120 160

200 150 200

Installation


11. Determine and note the contact wire height with the lifting force according to the Table "Orien-tation 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 plat-form, use it as the reference point. The installation platform must then not be raised or lowered until the lightweight section insulator has been installed.

6.2 Necessary tools

• open-ended spanners, sizes 13 (M8), 17 (M10) and 19 (M12)• double-ended ring spanners (straight), sizes 13 (M8) and 17 (M10); DIN 387B/ISO 3318 • torque spanner with straight socket, sizes 13 (M8) and 17 (M10) (up to 100 Nm)• spirit level• sheet metal cutter or metal saw• contact wire measuring device• spring balance (20 kg)• tensioning device with the contact wire stringing grips and sling• piece of plain hard wood and copper hammer or contact wire straightening machine• folding rule• flat nose pliers

h sec

tion

insu

lato

r

h con

tact

wire

Installation


6.3 Installation of suspension

1. Mount the dead-end clamps (11) suitable for the messenger wire on the end fittings (7) of the insulating rod.

2. Calculate the length of the catenary wire section to be cut out.

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. Cut the catenary wire.

5. 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. Check the connections between the insulating rod and the catenary wire.

7. Carefully load the catenary wire with the weight of the installed suspension and remove the tensioning device.

NOTEThe dead-end clamps (11) are not included in the scope of delivery of the suspension and must be ordered sepa-rately.

ATTENTIONBending 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.

Installation


6.4 Assemble lightweight section insulators

6.4.1 Lightweight section insulator with one insulating rod

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.

NOTEThe 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 on the suspension straps at the same time.

ATTENTIONBending 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.

120 m

m

Installation


3. Cut the contact wire.

4. Place the lightweight section insulator on the contact wire symmetrically to the insulating rod in the catenary wire.

5. Hook the ring hooks of the turnbuckles of the suspension into the suspension straps of the lightweight section insulator.

6. 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.

Installation


8. Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening torque is MA = 43 Nm.

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.

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 insu-lator is then loaded with the contact wire tensile force.


15. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section insulator" on page 27.

6a

120 m

m

Installation


6.4.2 Lightweight section insulator with two insulating rods

1. Place the lightweight section insulator on the contact wire symmetrically to the insulating rod in the catenary wire.

2. Hook the ring hooks of the turnbuckles of the suspension into the suspension straps of the lightweight section insulator.

3. 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.

4. 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.

5. Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening torque is MA = 43 Nm.

6a

Installation


6. 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.

7. Retighten the screws on the clamps (6a) for outer attachment of the runners once more to a torque of 43 Nm.

8. Lock the nuts on the clamps (6a) for outer attachment of the runners.

9. 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.

10. Bend the end section of the contact wire a few millimetres upwards.


12. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section insulator" on page 27.

120 m

m

Installation


6.5 Adjust lightweight section insulator

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. Carry out the fine adjustment of the suspension at the turnbuckles.

3. 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 (AC-100) 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

NOTEComplete all installation and adjustment work on the entire tensioning section before you adjust the lightweight section insulator.Install the components which influence the height of the lightweight section insulator, such as shunt straps, before you adjust the lightweight section insulator.If the lightweight section insulator has to be short-circuited temporarily by means of a shunt strap, install the shunt strap before you adjust the lightweight section insulator. In doing so, maintain a minimum distance of 3 m ahead of and behind the lightweight section insulator both on the contact wire and on the catenary wire. Lead the shunt strap over the lightweight section insulator in order to bring the strap into the area of the catenary wire.

Installation


this purpose, the clamps (6a) for outer attachment of the runners must be repositioned in the elongated holes.

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. Tighten the screws on the links slightly.

6. 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.

8. In case of a deviation, reset this adjustment accordingly.

NOTEThe 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.

6a

round hole elongated hole

Installation


Checking the adjustment "A"

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 trans-ferred smoothly to the runners. The pantograph must not strike the inner or the outer ends of the runners.

Passing the lightweight section insulator with a pantograph

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.

3 runner 13a clamping plate of the end fitting4 insulating rod 14 Measuring tool 4a end fitting of the insulating rod 15 spirit level

A Adjustment between bottom of clamping plate (13a) and bottom of runners (B)B Bearing surface for measuring device after spirit level has been placed across bottom of runners

X

A =

4 m

m

13a

B

14

15

detail X

Installation


12. Secure the turnbuckles additionally with a piece of wire.

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.

Disassembly


7 Disassembly

7.1 Disassembly

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 "Light-weight section insulator with one insulating rod" on page 22).

2. Disassemble the suspension of the suspension straps of the lightweight section insulator.

3. Disassemble the lightweight section insulator.

4. Assemble a new lightweight section insulator or place a section of contact wire with contact wire splices into the space.

5. Remove the tensioning device and contact wire stringing grips.

6. 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.

7. Disassemble the suspension.

8. Insert a new piece of catenary wire.

9. Remove the tensioning device and catenary wire stringing grips.

7.2 Disposal and recycling

The lightweight section insulators have been produced out of materials which for the most part can be disposed of in an environmentally friendly manner and properly recycled.

A prerequisite for the disposal is that the lightweight section insulator is in a condition correspon-ding to correct and proper usage. Parts which cannot be recycled must be correctly disposed of.

We can provide help with disposal and recycling. In this respect, please contact your local Siemens company.

NOTEThe 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 at the suspension straps at the same time.

ATTENTIONBending 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.

Maintenance


8 Maintenance

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.

8.2 Preventive maintenance

Carry out the maintenance work according to the evaluation of inspection. The type and scope of maintenance as well as maintenance intervals are determined by the respective conditions, i.e. climatic conditions, degree of contamination and the line load. Any faults discovered during the service must be rectified.

WARNINGDeath 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.

Type of system AC system DC system

Inspection interval after commissioning

• every two years or• after about 200.000 pantograph passages

• yearly or• after about 100.000 pantograph passages

Part to be inspected Inspection purpose EvaluationRunner (3a), (3b) Determine degree of

wear- 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)

Contact wire dead-end clamp (1)

Check bolted connections

Use a torque wrench to check the bolted connections (tightening torque MA = 60 Nm).

Insulating rod (4) Determine degree of contamination

Determine degree of wear

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).

Suspension Check bolted connections

Check the connections between the insulating rod and the catenary wire

Maintenance


8.2.1 Rotate insulating rod

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 dia-meter (see Figure "Insulating rod wear" on page 33.

The diameter of an insulating rod is 20 mm.

Insulating rod wear

Rotate insulating rod

13a clamping plate of the end fitting

ATTENTIONThe 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.

20

15...

13

15...

13

dimension in mm

turned 180° turned 90° turned 180° replace

17.5

...1

6.5

17.5

...1

6.5

wear zone

13a

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).

2. Loosen the screws at both clamping plates (see Figure "Rotate insulating rod" on page 33), in which the insulating rod is fixed.

3. Rotate the insulating rod simultaneously at the ends into the desired position.

4. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm.

5. Replace the insulating rods when the wear of material is roughly 3 mm on all sides.

8.2.2 Cleaning the insulating rod

If necessary, remove dirt deposits from the insulating rod using water mixed with a commercially available detergent. Do not use any implements with sharp edges, e.g. machining tools, which might damage the PTFE coating on the insulating rod.

8.3 Corrective maintenance

8.3.1 Replace runners with arcing horns

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 insu-lator, rotated and tightly secured again without having to bend the insulating rod in the process. Avoid causing any distortion in the catenary system.

ATTENTIONOnly original spare parts supplied by Siemens AG may be used for maintenance work.In the event of a repair, contact your Siemens agency.

NOTEIf track superelevation is present, the gradient of the runners to each other transversely to the track is to be deter-mined with a spirit level before removal and is to be taken into account during adjustment of the new runners.

ATTENTIONDamage 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.

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).

Areas of greatest runner wear

1. Remove the screws and the links for the height adjustment of the runners.

2. Remove the runners.

3. Fix the new runners.

4. Repeat the handling instructions 1 to 3 for the other three runners, if necessary.

5. Adjust the runners or the lightweight section insulator as described in Section 6.5 "Adjust light-weight section insulator" on page 27.

3

100

3

AB

detail A detail B

dimensions in mmwear zone

Maintenance


8.3.2 Replace insulating rods on the lightweight section insulator

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).

2. Loosen the screws at the ends of the clamping plates.

3. Remove the insulating rod.

4. Insert the new insulating rod.

5. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm.

8.3.3 Replace the insulating rod in the catenary wire

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).

2. Remove the dropper wires from the insulating rod.

3. Disconnect the insulating rod from the wedge-type dead-end clamps of the catenary wire.

4. Fix the dropper wires to the new insulating rod.

5. Connect the insulating rod to the wedge-type dead-end clamps of the catenary wire.

6. Check the connections between the insulating rod and the catenary wire.

7. Remove the tensioning device.

NOTEThe insulating rods can be damaged by incorrect transport. Always pick up an insulating rod with both hands and carry it so that the weight of the insulating rod cannot cause it to sag in the middle.

ATTENTIONBending 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 insu-lator 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.

NOTEThe insulating rods can be damaged by incorrect transport. Always pick up an insulating rod with both hands and carry it so that the weight of the insulating rod cannot cause it to sag in the middle.

ATTENTIONBending 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.

Technical data


9 Technical data

9.1 Lightweight section insulator

9.1.1 Lightweight section insulator for nominal voltage up to 3 kV DC

9.1.2 Lightweight section insulator for nominal voltage 15 kV AC

Type / Order number 8WL5545-7A 8WL5545-8A 8WL5545-8ACNominal voltage DC [kV] 3 3 3

Clearance in air [mm] 60 60 60

Creepage distance [mm] 450 450 450

Weight [kg] 13.0 13.8 15.1

Maximum permissible operating load [kN] 30 30 30

Minimum failing load [kN] 90 90 90

Number of insulating rods 2 2 2

Number of contact wires 1 2 2

Contact wire distance [mm] – 28 40

Cross-section of contact wiresto be connected acc. to EN 50149

Other cross-sections of contact wires

AC/BC-80 to 150, Cu-ETPAC/BC-80 to 150, CuAg0.1AC/BC-80 to 120, CuMg0.5Ri161, Cu-ETP (British Standard 23)CTHA-85/-120 (China Standard)

Type / Order number 8WL5545-0A 8WL5545-1A Nominal voltage AC [kV] 15 15

Clearance in air [mm] 120 120

Creepage distance [mm] 760 760

Weight [kg] 13.0 14.9

Maximum permissible operating load [kN] 15 30

Minimum failing load [kN] 45 90

Number of insulating rods 1 2

Number of contact wires 1 1

Cross-section of contact wires to be connectedacc. to EN 50149


AC/BC-80 to 150, Cu-ETPAC/BC-80 to 150, CuAg0.1AC/BC-80 to 120, CuMg0.5Ri161, Cu-ETP (British Standard 23)CTHA-85/-120 (China Standard)

Technical data


9.1.3 Lightweight section insulator for nominal voltage 25 kV AC

9.2 Suspension (Accessories)

9.3 Materials

Type / Order number 8WL5545-2A -3A -4A -4AC -4AD

Nominal voltage AC [kV] 25 25 25 25 25

Clearance in air [mm] 220 220 220 300 300

Creepage distance [mm] 1200 1200 1200 1200 1400

Weight [kg] 15.9 14.1 15.9 16.5 19.66

Maximum permissible operating load [kN] 30 15 30 30 30

Minimum failing load [kN] 90 45 90 90 90

Number of insulating rods 2 1 2 2 2

Number of contact wires 2 1 1 1 1

Contact wire distance [mm] 28 – – – –

Cross-section of contact wires to be connectedacc. to EN 50149


AC/BC-80 bis 150, Cu-ETPAC/BC-80 bis 150, CuAg0.1AC/BC-80 bis 120, CuMg0.5Ri161, Cu-ETP (British Standard 23)CTHA-85/-120 (China)

Type / Order number 8WL5545-5A 8WL5545-6A 8WL5545-6ADFor section insulator 8WL5545-0A/-1A/

-7A/-8A/-8AC8WL5545-2A/-3A/-4A/-4AC

8WL5545-4AD

For nominal voltage DC [kV]AC [kV]

315

–25

–25

Maximum permissible operating load [kN] 30 30 30

Minimum failing load [kN] 90 90 90

Minimum creepage distance [mm] 1350 1750 1950

Weight [kg] 6.13 6.63 6.73

Part MaterialClamping fittings CuNiSi (Copper-Nickel wrought alloy)

Runners with arcing horns Copper

Insulating rods (section insulator) GRP (Glass-fiber reinforced plastic), PTFE

Insulating rods (suspension) GRP (Glass-fiber reinforced plastic), silicone

End fittings (suspension) stlSt (Stainless steel)

Turnbuckles stlSt (Stainless steel)

Rod pulley Polyamide, CuSn (Tin bronze)

Dropper wire 16f BzII (Bronze, strength grade II)

Technical data


9.4 Spare parts

9.5 Accessories and tools

Description Order numberRunner long for section insulator 25 kV 8WL5548-3B

Runner short for section insulator 25 kV 8WL5548-3D

Runner long for section insulator 25 kV (8WL5545-4AC) 8WL5548-3BC

Runner short for section insulator 25 kV (8WL5545-4AC) 8WL5548-3DC

Runner long for section insulator 25 kV (8WL5545-4DC) 8WL5548-3BD

Runner short for section insulator 25 kV (8WL5545-4DC) 8WL5548-3DD

Runner long for section insulator 15 kV 8WL5548-3F

Runner short for section insulator 15 kV 8WL5548-3H

Runner long for section insulator 3 kV 8WL5548-3K

Runner short for section insulator 3 kV 8WL5548-3M

Insulating rod for section insulator 25 kV (creepage distance 1200 mm) 8WL5548-0A

Insulating rod for section insulator 25 kV (creepage distance 1400 mm) 8WL5548-0H

Insulating rod for section insulator 15 kV 8WL5548-0B

Insulating rod for section insulator 3 kV 8WL5548-0C

Insulating rod for suspension 25 kV (creepage distance 1750 mm) 8WL5548-5CB

Insulating rod for suspension 25 kV (creepage distance 1950 mm) 8WL5548-5DD

Insulating rod for suspension 3 kV and 15 kV 8WL5548-5CC

Description Order numberContact wire stringing grips 8WL7140-0

Sling 8WL7142-7

Siemens AGIndustry SectorMobility DivisionTurnkey SystemsP.O.Box 32 4091050 ErlangenGermany

[email protected]/mobility/electrification

Sicat 8WL5545Operating Instructions / Version 3.2.2A6Z08110337684 / Status: 2008-11-20

Subject to change without prior notice!