Installation Instructions

Transcription

1 Installation Instructions EXCLUSIVE AUSTRALIAN DISTRIBUTORS

2 Mon9 Installation of helical dead ends General: Dead-end will be looped on delivery (fig.1). The particular wires of dead end are agglutinated into a bundle which is sanded inside. Both legs are provided with a coloured marking near the loop to mark the point where both legs of dead-end shall be wound for the first time around the conductor respectively around the guy grip (see arrow on fig.1). Fig. 1 Preparations: (Required only for conductors with run out in the loop) Conductor end shall be tied off by 2 to 3 laps of Tesa or adhesive tape, straightened and aligned. Assembly of dead end: 1. Dead end loop shall be protected from abrasion by means of a thimble any. 2. Put conductor resp. guy grip into one of the two legs of dead end at the coloured marking. Then wind these legs of dead end once around the conductor (fig. 2). Fig. 2 Stand: 17. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helical dead ends/ 1 / 65

3 In the event of conductors and guy grips which shall be carried up to the loop only, ends shall project above marking by about 2 to 3 cm (fig. 3). Fig Put in now also the second leg of dead end at the marking and wind it also once or twice around the conductor (fig. 4). Fig Twist both legs simultaneously except for about two pitches (fig. 5). Stand: 17. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helical dead ends/ 2 / 65

4 Fig Wind up now each end of leg separately (fig.6). Regard should be paid during winding that legs of dead-end do not slide on the conductor. Fig. 6 In general, ends of wire bundle will snap automatically in their preformed position. In the event that this, exceptionally, should not be the case, wires may also be wound individually by means of a screw driver, if necessary. Stand: 17. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helical dead ends/ 3 / 65

5 Mon10 Installation of armour grip suspension General The armour grip suspension unit, as shipped, consists of a set of armor rods, two halves of the bone-shaped neoprene insert and an aluminium suspension clamp (fig. 1). fig. 1 It is recommended to wear gloves when mounting the armor rods to protect the fingers from getting pinched. Installation 1. Mark the conductor at the mounting position with a color marker or similar. 2. Fix both halves of the neoprene insert at the marking with sticky tape in such a way that one half is on top of the conductor and one half below the conductor (fig. 2). The gap between the halves should lie in the horizontal plane. Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 4 / 65

6 fig Place a first rod in parallel with the conductor with the center marking of the rod at the waist of the neoprene insert. Start to wind the rod around the conductor at one side of the neoprene insert. Leave the end of the unmounted for about one pitch length (fig. 3). Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 5 / 65

7 fig Wind the rod around the conductor on the other side of the neoprene insert (fig. 4). Leave the end of the rod unmounted as well. Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 6 / 65

8 fig Mount a second rod as described in paragraphs 3 and 4 on the opposite side of the conductor (fig. 5). Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 7 / 65

9 fig Mount the remaining rods one after another as described in paragraphs 3 and 4. After installation the rods should be equally spaced around the neoprene insert (fig. 6). Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 8 / 65

10 fig To finish installation of the rods wind them on the conductor, at each end simultaneously (fig. 7). Normally, the ends of the rods snap in their factory-formed end position. Should the rod ends, inadvertently, be in a cross-over position use a screw driver to put them in correct position. Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 9 / 65

11 fig Install the aluminium clamp at the waist of the cage formed by the rods around the neoprene insert. If the aluminium clamp is of the hinged type (the two clamp halves connected with a hinge) place the hinge below the conductor and fasten the clamp screw (with hexagon socket) carefully (fig. 8). If the clamp is a conventional one (clamp with a keeper) fasten the clamp screws carefully. Torque of M8-Screws: 23 Nm Torque of M10-Screws: 46 Nm Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 10 / 65

12 fig Suspend the clamp in the pair of cranked straps (fig. 9). Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 11 / 65

13 fig. 9 Stand: 26. Juni 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of armour grip suspension/ 12 / 65

14 Mon17 Installation of Avibra-Vibration damper 1... Optical fibre aerial cable 2... Avibra-Vibration damper 3... Gripping section 4... Damping section Assembly: Avibra vibration dampers are installed by wrapping first the gripping section (smaller helix) and afterwards the damping section on the optical fibre aerial cable. The damper must always be installed in such a way that the gripping section is placed towards the tower and the damping section towards the free span. <!--[endif]--> No special tools are required for installation. Avibra vibration dampers can - even subsequently - be installed without problems on any existing optical fibre aerial cable. For mounting two or more Avibra vibration dampers in series please look at the special RIBE damper location sketch for the distance between them. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of Avibra-Vibration damper/ 13 / 65

15 Mon39 Installation of patch rods for conductors and OPGW General Patch rods are capable of re-establishing the full electrical and mechanical performance of a conductor or OPGW in the case that up to 100 % of the outer layer wires of conductor or OPGW are damaged. In case of damage to up to 25 % of the outer layer wires shorter patch rods can be used which are not gritted (for example: RA ). In case of more extensive damage to the outer layer wires patch rods have to be used which have greater length and which are gritted with conductive grit (for example: RA s). Patch rods are delivered as 3 to 4 subsets consisting of 3 to 5 pre-bundled rods which are glued together for ease of installation. For rod diameters of 7.87 mm and more patch rods come as a set of single rods. For overall lengths of 600 mm and more, patch rods are provided with a colour marking to mark their middle. Before Installation The conductor or OPGW must be carefully cleaned at the point of application of the patch rods. Cleaning has to take place over a portion equal to half the overall length of patch rods in either direction from the damage. Use of a cleaning brush is recommended. Assembly Patch rods can be installed on loaded or unloaded conductors or OPGW. However, preference should be given to installation of patch rods on unloaded conductor or OPGW. It is recommended that unexperienced workers use finger gloves on assembly. A. Patch rods consisting of several subsets of rods 1. Start with putting one rod subset at the point of damage in such a way that the colour marking of patch rods coincides with the center of damage. Wind rods around the conductor or OPGW in one direction. Continue with winding the rods around conductor or OPGW in the other direction. It is important that damaged outer layer wires are put back in their original lay before applying the patch rods. 2. Put the second rod subset closely to the first one and wind it around the conductor parallel to the subset already in place. 3. Install the other rod subsets accordingly. Damaged wires of conductor or OPGW must not interfere with patch rods. 4. On finalisation of assembly, patch rods will show a closed coloured ring (in case of patch rods of more than 600 mm length only) being formed by the colour markings of the rods. Stand: 17. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of patch rods for conductors and OPGW/ 14 / 65

16 B. Patch rods consisting of single rods For rod diameters of 7,87 mm and larger, single helical rods will be supplied which are not gritted. Instead, a gritted grease has to be used. After cleaning of conductor or OPGW and prior to assembly of patch rods, this grease shall be uniformly applied on the conductor or OPGW along a portion corresponding to the length of patch rods. Assemble rod by rod. Procede according to A. Patch rods for copper conductor Assemble according to A. The rod subsets consist of pre-bundled and gritted copper rods. The grit must not be removed. Removal Patch rods can be removed and used again provided that they have not been permanently deformed forcibly. Stand: 17. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of patch rods for conductors and OPGW/ 15 / 65

17 Mon51 Installation of suspension rods for non-metallic cables (ADSS) and span lengths < 70 m General: The RIBE light-duty suspension set for non-metallic cables consists of suspension rods TG, reinforcing rods LG and a thimble eye. Data of fittings: TG-suspension rods Rod material: steel, h.d.g. The rods consists of a bundle with several rods. In the geometrical middle is a preformed loop. LG-reinforcing rods Rod material: steel, h.d.g. The rods consists of a straight bundle with several rods. In the geometrical middle is a paint mark. Ring type thimble Material: steel h.d.g. Cable: non-metallic cable (ADSS) Preparation of installation: Before installation it should be checked that the diameterrange indicated on the label of the rods matches the actual diameter of the cable to be suspended. It is recommend ti install the rods with protective gloves. Installation: 1) Start by mounting the reinforcing rods. Position the bundle of the reinforcing rods so that the paint mark is at the place where the cable is to be suspended. The paint mark has to be on the upper side of the cable. Stand: 03. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for non-metallic cables (ADSS) and span lengths 16 / 65

18 2) Wrap the reinforcing rods around the cable beginning from the paint mark to the end of the rods. 3) Insert the ring type thimble i the loop of the suspension rods. Attach thimble eye and suspension rods at the device at which the cable is to be suspended (bolt, hook, shackle etc.). Bring the cable with reinforcingto the suspension rods and wrape the suspension rods around the cable. Start from the center mark of the reinforcing rods. The suspension rods have to fit in between the reinforcing rods. The suspension rods most not cross over the reinforcing rods. Stand: 03. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for non-metallic cables (ADSS) and span lengths 17 / 65

19 Stand: 03. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for non-metallic cables (ADSS) and span lengths 18 / 65

20 4) Mounting is finished when the suspension rods are completely wraped around the cable. Stand: 03. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for non-metallic cables (ADSS) and span lengths 19 / 65

21 Stand: 03. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for non-metallic cables (ADSS) and span lengths 20 / 65

22 Mon67 Installation of helically formed dead end consisting of protection rods and outside dead end Type of dead ends: 1. RW-protection rods and AW-dead end 2. URA-protection rods and AG-dead end 3. URG-protection rods and AG-dead end Data of spirals: 1) Protection rods Rod material: Aluminium-clad steel (RW-protection rods) Aluminium-alloy (URA-protection rods) Steel, h.d.g. (URG-protection rods) The set consists of several bundles. The bundles consist of several rods. The bundles have a black mark in center. 2) Dead end Rod material: Aluminium-clad steel (AW-helical dead end) Steel, h.d.g. (AG-helical dead end) Remark: The Protection rods and dead end have opposite layer direction. Cable: OPGW, ADSS or Phase conductor Preparation of the cable: The installation starts with attaching the protection rods at center mark. This attachment point has to be fixed by metering. 1. Installation of protection rods 1.1 The bundle with largest number of rods is mounted first. Attach the first bundle at the marked point. Wrap 2 pitch lengths around the cable in direction of one bundle end. Fig Attach the other bundles and wrap two pitch lengths around the cable. The bundles now show an approximately complete layer on the cable. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 21 / 65

23 Fig Wrap two bundles (on side) that are opposite (180 ) on cable complete around the cable. Fig Wrap the remaining bundles (one side) complete around the cable. Now one end of the protection rods is complete. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 22 / 65

24 Fig Wrap the other side of the bundles according to step 1.3 and 1.4 around the cable. Fig Installation of protection rods is complete. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 23 / 65

25 Fig Installation of helical dead end 2.1 Hang thimble in the loop of dead end. At the towerside the protection rods of the dead end assembly shall be installed in such a way that it jut out over the thimble for about 12 cm. Fig The first leg of the dead end will be attached at the mark and wrapped on for one pitch length. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 24 / 65

26 Fig The second leg is attached and wrapped on for the first one pitch length. Fig Both legs are wrapped on simultaneously for further pitch lengths. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 25 / 65

27 Fig At the end the two legs are divided into bundles of 3 to 4 rods and wrapped on. Fig Now helically formed dead end is completely installed.. Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 26 / 65

28 Fig. 12 Fig. 13 Stand: 22. Mai 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of helically formed dead end consisting of protection rods and outside dead end/ 27 / 65

29 Mon69 Installation of suspension rods for ADSS and medium span lengths from m General: Suspension rods consisting of TG-suspension and UTA-protection rods are designed for vertical loads up to 5 kn. They are used for span lengths from m approximately. The loop of the TG-suspension rods is stabilized and protected against abrasion by a ring type thimble. Data of fittings: TG-suspension rods Rod material: steel, h.d.g. The set consists of one bundle with several rods. The bundle have a loop in the center. UTA-protection rods Rod material: Aluminium alloy The protection rods consists of three bundles with several rods. Each bundle has a black mark in the center. Ring type thimble Material: steel, h.d.g. Remark: The UTA-protection rods and TG-suspension rods have opposite layer direction. Cable: ADSS 1. Installation of UTA-protection rods 1.1 The bundle with largest number of rods is mounted first. Attach the first bundle at the marked point. Wrap 2 pitch lengths around the cable in direction of one bundle end. 1.2 Attach second two bundles. Wrap 2 pitch lengths around the cable. 1.3 The bundles now show an approximately complete layer on the cable. Stand: 07. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for ADSS and medium span lengths from m/ 28 / 65

30 1.4 Wrap all bundles (on side) complete around the cable. 1.5 Now one end of the protection rods is complete. 1.6 Wrap the other side of the bundles according to step 1.4 and 1.5 around the cable. Stand: 07. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for ADSS and medium span lengths from m/ 29 / 65

31 1.7 Installation of UTA-protection rods is complete. 2. Installation of TG-suspension rods 2.1 The loop of first leg of TG-suspension rods attachs onthe black center mark of the UTA-protection rods. The leg will be wrapped around the UTA-protection rods beginning from the blank center mark to end of protection rods. 2.2 Insert the ring type thimle in the loop of TG-suspension rods. The second leg wrap around the cable. 2.3 The installation of suspension rods is complete and hang in the ring type thimble in the suspension hook. Stand: 07. August 2006 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of suspension rods for ADSS and medium span lengths from m/ 30 / 65

32 Mon75 Installation of Stockbridge-type vibration dampers with bolted clamps on OPGW Before installation: Each delivery of Stockbridge-type vibration dampers for OPGW will come with a placement chart indicating the correct placement of the vibration dampers for the particular application. The vibration dampers have to be installed according to the placement chart to ensure proper function of the vibration dampers. Make sure that the fittings of the tension assemblies (helical protection rods, helical dead-ends and thimbles) and suspension assemblies (armour grip suspension units) were installed according to the respective mounting instructions. Make sure that the correct damper type as indicated in the placement chart will be mounted at tension assemblies and suspension assemblies, respectively. Use a torque wrench for tightening the clamp bolt. Tightening torque M a : 46 Nm for M10-Bolts 60 Nm for M12-Bolts Placement of vibration dampers at a tension assembly 1...Fibre optic cable 2...Thimble...F xxxx/x 3...Helical dead-end... AW xxx xxx 4...Protection rods...rw xxx xxx lis 5...Vibration damper...f 14 xxx/x Kb...Ma = xx Nm L 1 x,x m L 2 = x,x m L 3 0,2 m L 4 0,4 m Placement of vibration dampers at a suspension assembly 1...Fibre optic cable 2...Armour grip suspension unit...lta xxx xxx/x lis 3...Vibration damper...f 14 xxx/x Kb...Ma = xx Nm L 1 = x,x m Stand: 20. März 2007 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of Stockbridge-type vibration dampers with bolted clamps on OPGW/ 31 / 65

33 Mon77 Installation of Stockbridge-type vibration dampers with helical fixing Before installation: Each delivery of Stockbridge-type vibration dampers for OPGW will come with a placement chart indicating the correct placement of the vibration dampers for the particular application. The vibration dampers have to be installed according to the placement chart to ensure proper function of the vibration dampers. Make sure that the fittings of the tension assemblies (helical protection rods, helical dead-ends and thimbles) and suspension assemblies (armour grip suspension units) were installed according to the respective mounting instructions. Make sure that the correct damper type as indicated in the placement chart will be mounted at tension assemblies and suspension assemblies, respectively. Placement of vibration dampers at a tension assembly 1...Fibre optic cable 2...Thimble...F xxxx/x 3...Helical dead-end... AW xxx xxx 4...Protection rods...rw xxx xxx lis 5...Vibration damper...b xxx xxx/x...with helical rods TW xxx xxx L 1 0,5 m L 2 = x,x m L 3 0,4 m Placement of vibration dampers at a suspension assembly 1...Fibre optic cable 2...Armour grip suspension unit...lta xxx xxx/x lis 3...Vibration damper...b xxx xxx/x...with helical rods TW xxx xxx L 1 = x,x m The damper location sketch shows the necessary information for installation of vibration dampers. The rods for helical fixing are led through the clamping profile up to the center marking of the rods. Then the rods are wound on the left and on the right side of clamping profile on the OPGW or on the rods of armour grip suspension. Stand: 20. März 2007 Pfad: Mounting instructions/ RIBE-Optofit/ Installation of Stockbridge-type vibration dampers with helical fixing/ 32 / 65

34 MON22 General instructions for substation connectors bolted type The reliability and low electrical resistance depends strongly on the assembly accuracy! 1.) Preparation of connectors befor installation Estimate the type and position of connector contact surfaces (typical arrangements see fig 1 to 4) Wipe the contact surfaces of connector body with cleaning detergent and clean cloth Brush all smoth contact surfaces using a clean steel brush (approx. 30 strokes, until the brush is gripping ). Riffled contact surfaces in connector bodies may be brushed softly. NOTE: for Aluminium an Copper materials always use two different brushes with marking! Apply a thin film of contact grease immediate after brushing on the contact surfaces. NOTE: Use only clearly markked contact grease for bolted type connectors. Never use other or unknown greases! Proceed with other steps in order to finish the installation not later than 30 min. after teh initial contact surface brushing. DO NOT touch the prepared contact surfaces! fig. 1: Connector type A fig. 2: Connector type B fig. 3: Connector type C fig. 4: Flat terminal Stand: 10. September 2009 Pfad: Mounting instructions/ Medium and high voltage/general instructions for substation connectors bolted type/ 33 / 65

35 2.) Preparation of conductors / terminals before installation Remark: This paragraph applies also for the preparation of eventual sleeves and shims. Wipe the contact surface of conductor with cleaning detergent and clean cloth. This is also the only preparation of equipment terminals with electro-galvanised platings. Stranded conductors: Clean the contact surface in the proper portion of conductor using a clean steel brush (e. g. acc. catalogue sheet B198/1) Tubular conductors / Flat terminals: Clean the contact surfaces in the propper location using a clean steel brush or clean emery in the same manner as described in 1.). NOTE: For Aluminium and Copper materials always use two different brushes / emery with marking! Proceed with other steps (as described in 1.) and 3.)) in order to finish the installation not later then 30 min. after the initial contact surfaces brushing. DO NOT touch the prepared contact surfaces! 3.) Installation of connectors and flat terminal connections Bring the connector and conductor / terminal in the proper installation position. Follow fig. 5 for the installation of conductor ends and fig. 6 for eventual washer and nut installation. Fig. 5: Installation of conductor ends Fig. 6: Installing of nuts and spring washers Tighten the bolts in symetrical way (check the equidistance gap acc. fig. 1and 2). Alternating and crosswise apply the specific torque to the bolts using a torque wrench. Remark 1: For detail expalanation of crosswise tightening see fig. 7. Remark 2: Follow the torque setting values engraved on the connector bodies or given on the catalogue sheets. If no torque given, please see settings on table 1. Stand: 10. September 2009 Pfad: Mounting instructions/ Medium and high voltage/general instructions for substation connectors bolted type/ 34 / 65

36 Fig. 7: Alternating bolt tightening schema Fig. 8: Installation of cupal- and reduction sleeves Material of srews M8 M10 M12 M16 M20 A2f80 / Nm 46 Nm 80 Nm 190 Nm 380 Nm A2f70 15 Nm 29 Nm 51 Nm 120 Nm 240 Nm CuNiSi F49 20 Nm 39 Nm 68 Nm 160 Nm - Table 1: Recommended torque settings for hexagon bolts Check the installation, if neccesary re-tighten the bolts (1x). No further maintenance and retightening is neccesary. Stand: 10. September 2009 Pfad: Mounting instructions/ Medium and high voltage/general instructions for substation connectors bolted type/ 35 / 65

37 MON6 Insulator ties for post insulators type General Ties are delivered in two parts: each part consits of a number of helical wires glued together. The center is colour marked. Additionally colour marks are left and right besides the center mark to facilitate the mounting. Mounting of the tie 1. Conductor is to be removed from the roller after regulation of sag and placed in the head groove of post insulator. 2. Wind one half of the tie around the conductor starting from the center (fig. 1). The winding starts by finishing windung at one end of tie and continued with the second end (fig 2). fig.1 If the ends of the wires are lying upon another they have to be correctly arranged 3. Insert second half of tie through hole of post insulator. Then bend one end of the half of tie up, wind it around the conductor and check the mark being at the same position as the mark of the first half already mounted. It s easy to wind the end into the gap of the first half (figure 4). Wind the other end of second half onto the conductor in the same way (figure 5). The mounting is nows finished. This tie is able to carry a single sided tensile force of 0,5-1 kn. fig.2 Stand: 05. Juni 2008 Pfad: Mounting instructions/ Railway fittings/insulator ties for post insulators type / 36 / 65

38 fig. 3, 4, 5 and 6 Ties with increased tensile force 4. To increase the tensile force, commonly called peak tensile force for medium voltage towers (approx. 3 kn), the tie can be reinforced by a wire joint. Take one wire out of the tie using a srew driver and uncoil it up to the side mark (figure 7). Wind this wire around like a wire joint with narrow windings (figure 8). Press the Stand: 05. Juni 2008 Pfad: Mounting instructions/ Railway fittings/insulator ties for post insulators type / 37 / 65

39 end of the wire with a universal pliers to the tie (figure 9). Make a same wire joint at the other side of tie (figure 10). The distance of wire tie to the post insulator limits the sliding ot the tie for single slided tension. fig. 7 Stand: 05. Juni 2008 Pfad: Mounting instructions/ Railway fittings/insulator ties for post insulators type / 38 / 65

40 fig. 8, 9 and 10 Stand: 05. Juni 2008 Pfad: Mounting instructions/ Railway fittings/insulator ties for post insulators type / 39 / 65

41 MON63 Inspection of tools and dies to press stainless steel compression type joints as per Ebs Tools and dies: To press the stainless steel joints acc. Ebs item number 6 (RIBE -No. F A05) compression tools with a compression force of 60 kn are used. The dies must have the reference code 16 PO and a compression width of 5 mm. The dies can hafe the shape like shown on fig. 1 and 2. During the pressing the dies have to be closed till impact! fig. 1: die set, with spring to open fig. 2: die set, for fastening on the tool by screw fig. 3: connector after compressing fig. 4: measure determination for examination of compressing Test procedure: Apart from the apparent examination of complete reasoning for the die sets with each compression regular measure examinations are recommended. In addition the measure of P in mm with a caliper gauge is to be determined at the pressed link like shown on fig. 4. Becomes a P max. = 12.8 mm exceeded, are the pressing tools and dies by experts to examine and the revision and/or the replacement too to arrange. Stand: 06. Februar 2009 Pfad: Mounting instructions/ Railway fittings/inspection of tools and dies to press stainless steel compression type joints as per Ebs / 40 / 65

42 MON65 Connecting clamp for contact wire (F01928) Before starting mounting the ends of contact wire have to be cleaned by a steel brush as shown on B198/1. Additional greasing of the bolts is not permitted. 1) for mounting on contact wire with standard shape the torque is 35 Nm 2) for mounting on contact wire with figure- 8 shape the torque is 25 Nm 3) when connecting both types of contact wire the relevant torque has to be used 4) tightening of bolts to be done in seriation I-II-III 5) bolts have to be retightened in the same seriation Stand: 26. November 2007 Pfad: Mounting instructions/ Railway fittings/connecting clamp for contact wire (F01928)/ 41 / 65

43 MON65S Montageanvising Skarvklämma fabr. RIBE F01928 (Banverket Art.nr.: ) Före montering måste anslutningsytan på kontakttråden rengöras från oxider och andra föroreningar med en stålborste. Se sidan B198/1 i katalogen. Extra infettning av bult(ar) eller klamma är ej tillåten. 1) Vid montering på rund kontakttråd - Åtdragningsmoment 35 Nm. 2) Vid montering på äldrr typ av "8-formad" kontakttråd - Åtdragningsmoment 25 Nm. 3) Vid skarving av kontakttråd enligt 1.) och 2.) ovan - Åtdragningsmoment 35 NM resp 25 Nm. 4) Skuvarna måste ansättas i ordningsföljd I - II - III. 5) Efter uppnådd driftbelastning (nyttig last) skall skruvarna kontrolldras i ordningsföljd I - II - III enligt moment ovan. Stand: 05. Februar 2009 Pfad: Mounting instructions/ Railway fittings/montageanvising Skarvklämma fabr. RIBE F01928/ 42 / 65

44 MON79 Assembly instruction for tension wheel assemblys Tension wheel with integrated cable brake for catenary lines with tension force up to 30 kn gear ratio 1 : 3 Tension wheel with integrated cable brake acc. drawing B NOTES Before starting the assembly, read the instruction carefully. Assembling is only permitted for personnel who is familiar with the contents of the instruction. Ignoring the notes might lead to serious health damages and significant property damages. Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 43 / 65

45 In operation, certain parts of electrical equipment are on hazardous electric potential. All persons performing installation and maintenance of this equipment must be aware of these hazards and must be familiar with the contents of the following instructions. Death, serious physical injury and damage to property can occur. Observe the safety regulations and warnings included in these instructions and read these instructions completely before installing this product. A correct and safe operation of the tension wheel can be guaranteed only after suitable transport, proper storage, erection, assembly,commissioning and careful maintenance. 1 Savety instructions The tension wheel may only be used for its intended purpose and only according to this assembly instruction. All other methods of use are forbidden unless explicit agreement has been issued by RIBE. All persons performing the assembly must be qualified adequately. That is amongst others the installation and assembly of the tension wheel, as well as working in accordance with, and on the basis of drawings, special tools as well as accident prevention and safety regulations. Basic knowledge regarding assembling and working on catenary systems is assumed. Attention should be paid to live-line working instructions and working close to energized equipment. Irrespective of these, the following five safety rules according EN apply: Before carrying out any work, do the following: 1. Isolate the plant 2. Secure against being switched on 3. Make sure there is no residual voltage in the plant 4. Earth and short-circuit the plant 5. Cover or safeguard live parts 2. Application Tension wheels are used for retensioning of the contact wire, the catenary wire or both at the catenary line. The tension wheel keeps the height of the contact wire and the catenary wire constant due to tem-perature changes. It also assures a specified, almost constant traction. The tension wheel in reference to drawing B624006, which has a mass guidance near the tower, is used for tension forces up to the maximum of 30 kn. 3. Assembly Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 44 / 65

46 fig. 1: Tension wheel acc. to drawing B624006, Assembly (1) Suspension (2) Balancing plates (6) Complete wheel (7) Complete brake cable (10) Clip (11) Adjusting plates for mass guidance rod (18) Bolt M24x620, SW 36 (28) Wedge for fixing the cable to the weight set (29) Damping sleeve and adjusting for the brake cable M16, SW 24 (23) Special steel cable for tension set, diameter 9,5 mm (to be orderd separatly) (24) Special steel cable for weight set, diameter 9,5 mm (to be orderd separatly) (25) Wedge type dead end clamps (to be orderd separatly) (26) Mounting parts (to be orderd separatly) (27) Spacer (to be orderd separatly) Recommended tighting torques M A for screws and nuts: for M10 A2-80: M A = 46 Nm for M12 A2-80: M A = 80 Nm 4. Accesories Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 45 / 65

47 fig. 2: accesories (23) Special steel cable for tension set (tension cable) (24) Special steel cable for weight set (weight cable) (25) Wedge type dead end clamps, see RIBE-Catalogue B623/1 and B623/2 (26) Parts for fixation at tower (27) spacer, see RIBE-Catalogue B625/1 (30) Weight rod, see RIBE-Catalogue B624/3 with clip for weight supporting rods, see RIBE-Catalogue B624/4 (31) Weights (32) Weight guidance piece (33) Guidance rod with mounting parts an collar ATTENTION: The listed parts have to be ordered separately. 5. Assembling the special cables to the tension wheel (1) Suspension with drilling in the u-bar for brake cable (2) Balancing plates (7) Brake cable (29) Damping sleeve (40) Connection of the brake cable in the balancing strap (M12, WS 19) (41) Nut and counternut at the thread rod of the brake cable (M16, WS 24) fig. 6: Adjusting the brake cable NOTE: Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 46 / 65

48 For a duly assembly of the cables, the balancing with the tension wheel needs to be fixed into a bench vice or a similar fixture. The tension wheel must be freely rotatable in the balancing. CUTTING THE SPECIAL CABLE: Wrapping the special cable at both sides of the cut-off point with wire in order to prevent the special cable from detwisting after cutting. The wire layer must be as thin that it is possible to induct the cable into the cable pocket (B) at the large wheel or into the drilling (E) in the torque arm of the tension wheel (small wheel). To cut the cable, we recommend the use of an abrasive cutting machine. 5.1 Assembling the tension cable to the small wheel (see fig. 3) Cut the cable to convenient length Disburse the cable and remove possible cable torsions Pull the cable through the drilling (E) in the radius until both cable ends have the same length Secure the cable from shifting in the drilling (E) (e.g. with a wooden wedge) Starting inside, put the cable on both sides to each radius into the cable flutes of the small wheel Tighten the cable and turn the tension wheel into direction H by making one rotation Secure the position of the cable on the small wheel from removing with wire 5.2 Assembling the weight cable (large wheel) (see fig. 3) Cut the cable to convenient length Disburse the cable and remove possible cable torsions Pull the cable end through the opening in the contact surface of the large wheel (A) and the cable pocket (B) Form an adequately long loop with the cable end behind the cable pocket (B) Put the wedge (C) into this loop in the way that the bigger radius of the wedge lies in the loop radius Pull the cable loop with the wedge fitfully into the cable pocket, fix with a rubber mallet Wrap the cable with tight in abducent direction of the cable pocket by turning the tension wheel by 1 ½ rotations in direction G onto the large wheel Secure the position of the cable from removing with wire fig. 4:Cable assembly onto the tension wheel (7) Brake cable (23) Special steel cable for tension set (tension cable) (24) Special steel cable for weight set (weight cable) Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 47 / 65

49 6. Assembling the tension wheel to the tower joints fig. 5: Mounting the tension wheel Push the suspension (1) with the balancing (2) and the tension wheel (6) between the mount-ing parts (26) Push the bolt (18) 24 mm through the drilling of the mounting parts (26) and through the plates of the suspension (1) Secure the stud bolt with the adequate nut and split pin Set the tension wheel into operation by connecting the catenary system and the weights and mind that the rewind of the weight cable and the tension cable is in accordance to the tem-perature (in reference e. g. to RIBE drawing B ) Remove all tools used during the assembly (e. g. wooden parts, wire) Adjust the brake cable in reference to figure 6 The distance between the locknutted fixed nut (41) of the thread rod of the cable break and the damping sleeve (29) over the suspension (1) must be 3-5 mm (see figure 6). In order to adjust this distance, the brake cable has to be placed evenly in the brake cable flute and the tension wheel must be under load. (1) Suspension with drilling in the u-bar for brake cable (2) Balancing plates (7) Brake cable (29) Damping sleeve (40) Connection of the brake cable in the balancing strap (M12, WS 19) (41) Nut and counternut at the thread rod of the brake cable (M16, WS 24) fig. 6: Adjusting the brake cable Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 48 / 65

50 7. Maintanance The tension wheel is maintenance-free. After a cable disruption, the damping sleeve (29) has to be replaced. Before re-putting into operation, the tension wheel and also the brake cable must be visually checked for damages. Damaged parts must be replaced. 7.1 Changing the damping sleeve Before putting into operation after a cable disruption, the damping sleeve (29) has to be replaced. Unscrew the nuts (41) from the thread rod of the brake cable Replace the damping sleeve by a new one Re-screw the nuts (41) Re-adjust the brake cable as under section 5 described One damping sleeve is included within the delivery of the tension wheel as a spare part. It is attached captively in the drilling of the suspension (2). After the removal of that spare part, it has to be substituted shortly. The re-mounting of that spare part at the suspension of the tension wheel leads to a rapid clearance of a breakdown. The tension wheel is also fully functional without the damping sleeve. When putting the tension wheel into operation without any damping sleeve, the percussive energies, affecting the tower, are higher Replacing the brake cable ATTENTION: When changing the brake cable, the tension wheel must be load-free Disassembling the old cable Unscrew the nuts (41) from the thread rod of the brake cable Unscrew the nut and the screw at the cable socket of the brake cable at the collateral clip Remove the old brake cable Assemblin the new brake cable Put the thread rod of the brake cable into the upper drilling of the suspension (1) and attach two nuts M 16 (41) (tighten the nuts only per hand) Put the brake cable into the outer flute of the tension wheel (see figure 4) and pass the cable loosely round the tension wheel to the strap of the balancing (2) Fix the cable sleeve of the brake cable with the hexagon screw and the nut inside the balanc-ing (2) at the intended drilling After that, adjust the brake cable as under section 5 described (figure 6) 8. General For queries, spare part orders or alterations, please contact us and mention all order data. Address: Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 49 / 65

51 Richard Bergner Elektroarmaturen GmbH & Co. KG Bahnhofstr D Schwabach tel.:(+49) / fax: (+49) / For spare part requirements, please advise the position number mentioned in the figures. Subject to change without notice. No claims, as far as notes, illustrations and specifications are concerned. Errors excepted. A pdf-version of this assembly instruction is avaiable for download. Stand: 20. Mai 2010 Pfad: Mounting instructions/ Railway fittings/assembly instruction for tension wheel assemblys/ 50 / 65

52 MON117 section insulator Section insulator for catenary systems for TRAM and Industrial Railways up to 3 kv with skids made of copper acc. drawing and or similar as well as with insulated skids acc. drawing and B or similar Section insulator installed in Athens Operating electrical systems dangerous electrical voltages are existing in definite parts of these systems. Only persons knowing these danger and the contents of this mounting instruction are allowed to do the work. Severe hurts or death can occur if the mounting instruction and the use manual is not observed. Follow the warnings in this mounting instruction and read it carefully complete before installation. The section insulator fulfills its function if the transportation and storage, installation and mounting as setting into service and servicing were done carefully. 1 Safety advices Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 51 / 65

53 Use of section insulators is only allowed according this mounting instruction. Additional use and properties have to be especially confirmed by RIBE. The staff for installation must be qualified. This means they have to be familiar with the mounting, the construction of the section insulator as well as with the drawings, the special tools and the special regulations for preventation of accidents and safety regulations. Basic knowledge for mounting of catenary systems is assumed. Especially the regulations for hot line installation and installation next to systems switched on. We specially draw your attention to EN Pay attention to the five safety rules: Before start working: 1. Switch off 2. Secure against switching on 3. State system is free of voltage 4. Earthing and short-circuiting 5. Cover or barrier near alive parts 2 Use of section insulator These section insulators are used in catenary of TRAM (local trafic) and Industrial Railways. They are suitable for contact wire shape AC acc. to EN (equivalent Ri of DIN part 1) and separate the contact wire of the catenary into single, insulated switch and feeding sections. Depending on the installation position of section insulators, the catenary system and the pantographs used, speeds up to 80 km/h are permissible. Section insulators are suitable for DC systems with max. 3 kv and tensile loads up to 25 kn, skids and arcing horns are verticaly adjustable. In case of section insulators with copper skids and reinforced insolation, the skids can used as switching element or as partial under voltage. They can be installed without cutting the contact wires before. 3 Construction and extent of delivery 3.1 Construction The fundamental construction is shown in fig. 1 to 6. Hereby signify: item nomination item nomination 1 insulating strap 8 eye bolt with hanger 2 copper skid 9 eye bolt for adjusting of skid 3 insulating cross beam 9A supporting insulator (only in case of reinforced insolation) 4 arcing horn (left) 10 adjusting bolt for end fitting 5 arcing horn (right) 11 insulating skid 6 end fitting 12 adjusting piece for insolating skid 7 adjusting piece for arcing horn C marker for cutting the contact wire D contact wire has to flatten Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 52 / 65

54 fig1. fundamental construction of section insulator for fig 2: view A - A for fig. 1 fig 3: view A - A for fig. 1 in case of reinforced insulation fig. 6: view A - A and B - B for fig. 4 and 5 Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 53 / 65

55 fig. 5: section insulator acc. drawing B fig. 4: fundamental construction of section insulator for order No. fig. design L l1 l2 l3 weight skid arcing horns affect as protective section insulation suspension mm mm mm mm kg /2 short symmetric without single two insolating cross beams ,00 Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 54 / 65

56 order No. fig. design L l1 l2 l3 weight skid arcing horns affect as protective section insulation suspension mm mm mm mm kg /2 long symmetric without single two insolating cross beams , /3 long symmetric without reinforced two insolating cross beams , /6 without symmetric with single one insolating cross beam , without symmetric without single end fittings ,20 B /6 without asymmetric without single two insolating cross beams ,25 table 1: section insulator, design (other designs are avaiable). 3.3 Tests The section insulator was tested acc. pren 50119:2006. The mechanical test was performed with regard to an operating load of 25 kn, the specified minimum faillure load is 80 kn. Electrical test were carried out under dry and wet conditions acc. IEC / EN with positiv and negative lightning impulse withstand voltage (1,2/50 µs ) with a peak value of 63,8 kv and AC-Voltage of 35 kv/50hz for 1 min. 3.4 Transportation and storage Please check the section insulator after receipt for completeness and damage. The section insulators are delivered in special cases and have to remain in these cases till site. For storage please pay attention to the permissible stacking height. During handling the section insulator should not fall down or be thrown. 4 Mounting 4.1 Common hints The section insulators are pre-adjusted for use at contact wire AC-100 acc. to EN (equivalent Ri/RiS 100 of DIN part 1) and for use with current collector with plain panthograph slipper. In use of deviating contact wires or pantograph with curved current collectors the section insulator before the assembly is according to fig. 7 to adjust again (R = for pantograph with straight current collectors, R for pantograph with curved current collectors) Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 55 / 65

57 fig. 7: Adjustment of the section insulator on the used contact wire and the used pantograph Here it is to be noted that contact wire, arcing horns and (if available) the skid plates are adjusted in such a way that a simultaneous contact with the current collector of the pantograph is ensured. The adjustment is made thereby by adjusting the nuts characterized in the fig. 8 by 1, 2, 3 and 5. The isolation cross beam must be thereby parallel to the rail. Tightening of bolts is to be done with torque wrench. The indicated torque acc. fig. 8 must be kept. fig. 8: Recomended torques of the different bolt connections Mounting of section insulators should be preferable in straight tracks and in the center of the track (midth of track). Otherwise higher abrasion could occur. Represented by the use, the assembly of the distance section insulator is made possible for a suspension like it e.g. in the fig. 9 parallel to rail. It is to be made certain that in such a way the attachment of the suspension at the upper point of suspension (e.g. on the messanger wire with role) takes place that the longitudinal movement of the section insulator due to the temperature-dependent length variation of the contact wire to the consequence does not have change from height and side situation (for Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 56 / 65

58 example see picture on first page). 1 Loop insulator 2 Thimble 3 Dropper wire 4 Notch type connector 5 Thimble 6 Turnbuckle Bild 9: Suspension for section insulator (has to be ordered seperately; identification number e.g. B653006) The installation of the section insulator should take place with a negative contact wire sag from approximately 5 cm to get a better dynamic behavior of the overhead line to reach. 4.2 Proceed with the installation 1. For section insulators with insolation skid this is to be removed before the installation. In addition the adjusting nuts solve (No. 2 in fig. 8) and take the insolation skid out downward. 2. Adjust the Secktion insulator on the contact wire (fig. 11/12; position J, K) and bolt the srews for the contact wire clamps (No. 4 in fig. 8) of both ends (fig. 11; position G). Is to be paid attention to the correct seat of the final clamp in the groove of the contact wire. The screws have to be tighted with the recomended torque of 46 Nm. 3. Adjust the section insulator transverse to the driving direction, the contact level between disconnecting switches and current collectors must parallel to rail (fig. 10). fig. 10: Adjusting the section insulator transverse to the driving direction 4. The piece of contact wire (fig. 11; position H) present between the end pieces is at the marking notches (fig. 11; position K) to rip out and the contact wire (J) is to be bent according to fig. 12. Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 57 / 65

59 fig. 11: Cutting of the contact wire fig.12: Bending of contact wire after cutting 5. In case of section insulators with isolation skid, the insolation skid is to be replaced from downside and with the fine adjusting nuts to fasten (No. 2 on fig. 8). 6. If necessary, with the fine adjustment screws to adjust (No. 1 and 2 on fig. 8) the position deviation in longitudinal direction of the contact wire (J) within the range of the end pieces (G). 7. After the installation of the section insulator the adjustment is to be examined according to fig. 10 and placed behind if necessary. 5 Maintenance and service Section insulator have to be checked periodically for abrasion, minimum every second year or after collector passages. Checking is also necessary after short circuits in adjacent feeding sections. Extreme or different abrasion at slides show a bad mounting position. The regulation of the section insulator is then to be checked and adjusted. Passing the section insulator under load arcing could arise in negative feeding systems or caused by potential differences in adjacent feeding sections. The shape of the arcing horns guide the arcs away from insulating parts and extinguish them. It s important not to deform the arcing horns during transport, storage and installation and so not to prevent the arcs from moving by additional installations or insulation. Surfaces damaged slightly by arcs can be repaired by UV-resistant lacquer. If the surfaces are damaged severely the slides (item 8) resp. the whole section insulator have to be replaced immediately because of reduced insulation properties and tensile strength caused by penetrating water. Following parts have to be replaced and are offered by RIBE as spare parts: insulating strap, insulating cross beam, copper skid, insulating skid, arcing horns. 6 Common For questions, orders for spare parts or malfunction please adress us with all details of the order: postal adress Richard Bergner Elektroarmaturen GmbH & Co. KG Bahnhofstr D Schwabach phone: / fax: / For need of spare parts we ask for the identification number or the item numbers of the figures. Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 58 / 65

60 Subject to change without notice. No claims, as far as notes, illustrations and specifications are concerned. Errors excepted. Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/ section insulator/ 59 / 65

61 MON119 Section insulator Section insulator for catenary systems of Netherlands Railways (NS) acc. to drawings F 2611 and F fig. 1: Section insulator F 2611 installed at NS Operating electrical systems dangerous electrical voltages are existing in definite parts of these systems. Only persons knowing these danger and the contents of this mounting instruction are allowed to do the work. Severe hurts or death can occur if the mounting instruction and the use manual is not abserved. Follow the warnings in this mounting instruction and read it carefully complete before installation. The section insulator fulfills its function if the transportation and storage, installation and mounting as setting into service and servicing were done carefully. Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/section insulator/ 60 / 65

62 1 Safety advices Use of section insulators is only allowed according this mounting instruction. Additional use and properties have to be especially confirmed by RIBE. The staff for installation must be qualified. This means they have to be familiar with the mounting, the construction of the section insulator as well as with the drawings, the special tools and the special regulations for preventation of accidents and safety regulations. Basic knowledge for mounting of catenary systems is assumed. Especially the regulations for hot line installation and installation next to systems switched on. We specially draw your attention to EN Pay attention to the five safety rules: Before start working: 1. Switch off 2. Secure against switching on 3. State system is free of voltage 4. Earthing and short-circuiting 5. Cover or barrier near alive parts 2 Use of section insulator These section insulators are used in catenary of the Netherlands Railway (NS). They are suitable for contact wire shape AC acc. to EN (equivalent Ri of DIN part 1) and separate the contact wire of the catenary into single, insulated switch and feeding sections. Depending on the installation position of section insulators, the catenary system and the pantographs used, speeds up to 160 km/h are permissable. Section insulators are suitable for dc systems with max. 3 kv and twin contact wire (40 mm distance between contact wires) and tensile loads up to 2 x 10 kn. They can be installed without cutting the contact wires before. 3 Construction and extent of delivery 3.1 Construction The fundamental construction is shown in fig. 2 and 3. Hereby signify: item nomination item nomination 1 GRP-body complete 7 slide short 2 clamps 8 skid 3 clamping cover (left) 10 angle (complete) 4 clamping cover (right) 11 arcing horn (inside) 5 yoke 12 arcing horn (outside) 6 slide long Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/section insulator/ 61 / 65

63 fig. 2: Fundamental construction of section insulator (side view) fig. 3: Fundamental construction of section insulator (cross view) 3.2 Design versions order fig. design L L 1 max. allowed wight No. slides suspension mm mm speed km/h kg F /2 short with 2 yokes ,70 with 2 yokes Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/section insulator/ 62 / 65

64 order fig. design L L 1 max. allowed wight No. slides suspension mm mm speed km/h kg F elongated and 2 twin-contact wire clamps ,89 table 1: section insulator, design 3.3 Tests The section insulators were typetested to customer specification for mechanical working load Fzul = 2 x 10 kn. 3.4 Transportation and storage Please check the section insulator after receipt for completeness and damage. The section insulators are delivered in special cases and have to remain in these cases till site. For storage please pay attention to the permissible stacking height. During handling the section insulator should not fall down or be thrown. 4 Mounting 4.1 Common hints The section insulators are pre-adjusted for use at contact wire AC-100 acc. to EN (equivalent Ri/RiS 100 of DIN part 1) and for use with current collector with plain panthograph slipper. Tightening of bolts is to be done with torque wrench. The indicated torque must be kept. Mounting of section insulators should be preferable in straight tracks and in the center of the track (midth of track). Otherwise higher abrasion could occur. By use of the suspension to messenger wire mounting parallel to the surface of rail is possible. Please pay attention for fixing the suspension at the upper fixing point (for example via roll at messenger wire) to avoid changing in position of height and side when the contact wire varies its length caused by changes in temperature (for example see picture at cover page). The mounting of the section insulator should be realized with negative pre-sag for a better dynamic behaviour of the catenary. 4.2 Procedure for mounting Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/section insulator/ 63 / 65

65 fig. 4: mounting of the contact wires 1. Loosen upper nuts at yoke (fig. 4, item 23) while fixing the lower adjusting nuts (fig. 4, item 23 (k)) with a fork wrench against displacement. 2. Loosen nuts and bolts at the clamping covers (fig. 4, items 21 and 28) at both sides of the section insulator. 3. Place the section insulator onto the contact wires, adjust it and tighten the bolts of clamping covers (fig. 4, items 21 and 28) at both sides of the section insulator. Pay attention for exact position of end clamps in the grooves of contact wires (see fig. 5). Tighten bolts and counter nuts with the recommended torque of 33 Nm. fig. 5: section insulator with twin contact wire clamped 4. Tighten upper nuts at yoke (fig. 4, item 23) with a torque of 39 Nm and counter them while fixing the lower adjusting nuts by a fork wrench against displacement. 5. Adjust the section insulator cross and in driving direction, the contact level between section insulator and current collector must be parallel to the surface of rail (fig. 6). fig. 6: adjustment of section insulator cross the driving direction Fix the elongated slides of section insulators acc. to drg. No. F right and left at contact wire. Pay attention for exact position of twin contact wire clamp in the grooves of contact wire. Tighten the bolts with a torque of 39 Nm. Cut the contact wires even between the inner ends clamps of section insulator (at point A in fig. 4: for example with a coping saw). The ends of contact wires have to be flatened (round the lower edges). Check the regulation of section insulator after mounting followig fig. 6 and adjust if necessary. 5 Maintenance and service Section insulator have to be checked periodically for abrasion, minimum once per year or after collector passages. Checking is also necessary after short circuits in adjacent feeding sections. Extreme or different abrasion at slides show a bad mounting position. The regulation of the section insulator is then to be checked and adjusted. Stand: 04. Februar 2010 Pfad: Mounting instructions/ Railway fittings/section insulator/ 64 / 65