1 INTRODUCTION Alstom Transport NEW STINGER SYSTEM
SUMMARY 1. INTRODUCTION... 3 2. APPLICATION PURPOSE... 3 3. PRODUCT DESCRIPTION... 4 3.1. INSULATED CONDUCTOR RAIL SYSTEM FOR ENERGY SUPPLY... 5 3.1.1. SUPPORT HANGERS... 5 3.1.2. CONTACT RAILS... 5 3.1.3. RIGID JOINT CLAMPS... 6 3.1.4. FEEDER CLAMPS... 8 3.1.5. FIXED POINT HANGERS... 9 3.1.6. END CAP... 9 3.2. CURRENT COLLECTORS... 10 3.3. TROLLEY ON STEEL TRACK RAIL... 12 3.4. ELECTRICAL AND CONTROL PANEL WITH CABLES... 16 3.5. SOCKET FOR POWER TRANSMISSION TO THE VEHICLE AND RAPID SECURE LINK (ON DEMAND)... 18 4. TECHNICAL DATA... 20 5. MAINTENANCE INSTRUCTIONS... 22 2 INTRODUCTION Alstom Transport
1. INTRODUCTION The objective of this document is to provide a general description of the Stinger system and the relevant insulated conductor rail system for electrical power supply (installation recommendation). The following symbols and references are used in this manual to give instructions and warnings (cautions) of particular importance. These must always be strictly observed! NOTE: Refers to special information on how to use the equipment safely and efficiently. CAUTION: Warns of general dangers. Danger of injuries and damage to property. CAUTION: Warns of danger of electrical shock from live equipment. The operating instructions must always be kept at an on-site location near the Stinger System where they can be readily accessed. In addition to the operating instructions, general regulations regarding accident prevention and environmental protection are to be observed. Read the following assembly and maintenance instructions before starting the installation of the line. All personnel working on the conductor system should be correctly trained and authorized to operate on the energy supply system in compliance with relevant standards, regulations and laws. Furthermore only authorized and qualified maintenance personnel may work with the stinger system and conductor rail system and all personnel working has to able to recognize and avoid risks and possible dangers which may occur during operation. 2. APPLICATION PURPOSE Stinger systems serve as energy supply for rail vehicles as suburban and underground in depot and maintenance area separated from their main power supply (i.e. third rail or catenary). The power in these areas is supplied by current collector trolleys that can move on conductor rails fixed close to ceiling. The power received by a special cable over current collector trolleys is acquired to vehicle by proper sockets. This system is developed from inside applications. For the installation of the conductor rails and other working condition refer to following chapters. 3 INTRODUCTION Alstom Transport
3. PRODUCT DESCRIPTION The system is composed by different items grouped in the following sets: a) Insulated conductor rail system for energy supply b) Current collectors c) trolley on steel track rail d) Electrical and control panel with cables e) Socket for power transmission to the vehicle and rapid secure link (on demand) 4 PRODUCT DESCRIPTION Alstom Transport
3.1. INSULATED CONDUCTOR RAIL SYSTEM FOR ENERGY SUPPLY The insulated conductor rail ALINOX is a solution for the electric feeding of the Stinger system, suitable for load up to 1300 A. ALINOX is designed and realized in order to offer the best safety guarantees against accidental contact, according to the standard EN 60529, in particular the protection degree of housing is IP23. The conductor is made of aluminum and stainless steel and all bolts and nuts are in stainless steel. The system is available from 400 A up to 1300 A, and it could be used for power and control system. The range for admissible temperature for standard PVC insulating housing (addition of the ambient and the operating temperature) is -30 C +85 C, for the power of 900, 1100 and 1300 A is available NORYL insulating housing with maximum temperature up to 145 C. The insulated conductor rail system will be installed onto the existing support structure. The mechanical correct installation of the support arm must be checked before the start of conductor rail installation. 3.1.1. SUPPORT HANGERS The insulated conductor rail system will be installed onto the existing support structure. The mechanical correct installation of the support arm must be checked before the start of conductor rail installation. The support hangers have to be fixed to the respective iron brackets, which have been installed according to Pict. 1 where is shown the attachment to a I or H profile supporting beam, using two shaped plates, which position can be adjusted along the brackets, in order to fit it. This is only an example of installation, the system could be developed according to the requested layout. There are 2 types of support hanger : one for 750 V in DC and another for upper voltage composed with a fiberglass insulator up to 1500 V ( DC). Pict.1 (example of composition) Pict.2 The brackets have to be drilled keeping a minimum distance of 70 mm among the phases (when is a required a three phase system. The standard installation pitch of the brackets is 2 m maximum. Particular attention has to be paid during the installation of the brackets, fixing them to the wall or to the beam, in order to keep them as aligned as possible, to guarantee a straight and parallel run of contact rails. 3.1.2. CONTACT RAILS The rails are supplied in standard pieces 4 m or 6m long (according to the load); they must be assembled placing them side by side horizontally (at a minimum distance of 70 mm among them), hooking them on one side in the support hanger (pict 2) and then turning them in the support hanger until they are also attached to the other side. Another method of assembly consists on inserting the bar into the front of the support hanger. Then you have to slide the rail along, until it joins to the adjacent conductor rail. 5 PRODUCT DESCRIPTION Alstom Transport
Important Remark: the distance between each joint of one rail to the next, and the closest support hanger must always be 300 mm. In this way, being the support hangers mounted with pitch 2 m and being the rail 4 m long, the joints between two sections will be always 300 mm away respect to the support hangers. Pict.2 3.1.3. RIGID JOINT CLAMPS Pict.3 Before mounting the joint clamp on the line do the following operations: Brush with a metal (stainless steel) brush the contact surfaces of the joint clamp and contact rail. Apply a thin layer of white vaseline on the front surface of the contact rail or joint clamp The joint clamps are supplied in polythene bags containing the electric joint clamp, the insulating joint cover box. The electrical connecting clamp is composed of one stainless steel plate and an aluminium component assembled with 4 M10 screws, nuts, complete with washers (pict 3). Fit the clamp to the rail, space lightly the extremities of the rails and insert the upper part of the conductor between stainless steel plate and the aluminium component; move the other contact rail inserting the extremity as mentioned before and then tighten the 4 nuts taking care to centre the joint clamp (recommended torque 20 Nm). During the assembling phase make sure that the lower parts of the conductors are perfectly aligned and not twisted each other as shown in pict. 4 in order to avoid the outcome of the contact shoe due to the stumbling or bouncing over the joint passage. In case this happens, you have to align the extremities, with the help of two pliers positioned on the extremities and rotating them, one in the opposite sense of the other. 6 PRODUCT DESCRIPTION Alstom Transport
NO Pict.4 Remarks: in the unlikely case of presence of burrs near the extremities of the conductor, you must remove them before mounting the terminal, in order to avoid any irregular wear of the contact shoes. Then mount the two click half boxes that cover the joints as shown in the following photos. 1 2 3 4 7 PRODUCT DESCRIPTION Alstom Transport
3.1.4. FEEDER CLAMPS Pict.5 The feeder clamp must be installed where indicated in the installation diagram in substitution of a Joint Clamp. Before mounting the feeder clamp on the line do the following operations: Brush with a metal (stainless steel) brush the contact surfaces of the feeder clamp and contact rail. Apply a thin layer of white Vaseline on the front surface of the contact rail or feeder clamp. The feeder clamps are supplied in a polythene bag containing the electric feeder clamp, composed by a feeding plate, rigid joint clamp and related plate), two half-boxes with the relevant coupling self-tapping screws and four conical cable glands. The feeder clamps are realized with two components that have 4 holes for M10 screws in the lower part to be fixed to the conductor rail and 4 threaded holes M12 in the centre to link the feeder terminal. To assembly the clamp to the rail, slightly separate the extremities of the rails and insert the upper part of the conductor between the stainless steel plate and the aluminium component (pict. 5); move the other contact rail inserting the extremity as mentioned before and then tighten the 4 nuts taking care to centre the joint clamp. (Recommended torque 20 Nm). Cut the cone of the cable gland so that its diameter is slightly lower than the outer diameter of the cable; insert the extremity of the cable into the cable gland, connect the terminal connector at the extremity of the cable and then fix the terminal connector to the feeder clamp with the M12 screw (Recommended torque 40 Nm). Remove from one side, through a cutter, the round part of cable wall of the two half-boxes, on the side where the cable will be inserted; fit the cable together with cable gland between the two insulating half-boxes and then fix them one to the other through five self-threading screws. 8 PRODUCT DESCRIPTION Alstom Transport
3.1.5. FIXED POINT HANGERS Pict.6 They are used to determine a fixed point on the line. They must be mounted between two expansion joints or between an expansion joint and the extremity of the line. In case of lines for which expansion joints are not necessary, it will be enough to install one fixed point hanger per phase in the middle of the line. The fixed point hangers are similar to the support hangers, but they are equipped with a couple of half-joint (Pict.6). 3.1.6. END CAP The end caps are threaded on the contact rail at the extremity of the line. 9 PRODUCT DESCRIPTION Alstom Transport
3.2. CURRENT COLLECTORS The current collector is fixed to the brackets, realized with steel profiles 60x60x6. (pict.7). When you install the brackets on the IPE, you have to respect the distance of 220 mm between the support surface of the base of the current collector and the sliding surface of the contact shoe. Besides you have to do all the possible so that the axis of the fixing hole of the current collector is aligned with the fixing one of the support hanger of the overhanging line. (pict. 8). The contact shoe is then inserted into the two lower nibs of the insulated profile of the contact rail, which act as a guide. The derivation cable from the current collector (excluded from our supply, maximum section 25 mmq) is connected directly to the shoe, inserting it into one of the two lateral holes you find on the insulating cover containing the shoe. The insulating cap, already mounted, closes the other hole. REMARKS: the cable must have an abundant loop and be fixed to the lower arm of the current collector, by means of a hose clamp, to avoid limitations of the articulations of the contact shoe and consequently possible bad contacts on the conductor (pict. 9). Pict.7 10 PRODUCT DESCRIPTION Alstom Transport
Pict.8 Pict.9 11 PRODUCT DESCRIPTION Alstom Transport
3.3. TROLLEY ON STEEL TRACK RAIL The system is supported by means trolley that runs upon the structural beam. The operators is able to pull up the system by means rope in order to reach easily the exact connection point with the vehicle in maintenance area. The leading trolley is realized in order to ensure the maximum handling capacity motion on steel track rail without incurring in such problems of wear of the wheels having frequent maintenance activities as consequence. Warning: if the system is equipped with rapid secure link, is forbidden to fix the pull rope to the vehicle to be driven during train movement within maintenance area. In this way the rapid secure link is by passed! 12 PRODUCT DESCRIPTION Alstom Transport
Main characteristics: Weight : very light system thanks to usage of light materials for construction Anti-jump wheel : to increase the stability of the trolley during the motion on the beam Dumper : one on each side of a trolley to absorb the impact between two adjacent Stinger System 13 Alstom Transport
Contrast wheels : to increase the lateral stability during the motion along the beam Fast Installation : simplicity of installation thanks to the marks on the transverse beam 14 Main characteristics: Alstom Transport
Weld less : no welding to reduce the weight, increase the resistance and decrease the cost Expandability : possibility to add Signal Rails or Power Rails even on Stinger System already installed 15 Main characteristics: Alstom Transport
3.4. ELECTRICAL AND CONTROL PANEL WITH CABLES The product provides the relevant command and control of Stinger System in a selective mode. Each Stinger belonging to the same feeding line can be switched ON or switched "OFF" depending of operating needs. PENDANT REMOTE CONTROL DESCRIPTION: The operators using the pendant remote control above is able to activate or deactivate such system according to the following state condition: 1. Key security switch on remote control : ON 2. Rapid secure link connected (if equipped) 3. Jupiter plug connected to the vehicle 4. Green Light on control panel switch ON automatically If all the above states are satisfied, the system is in Stand-by state and the operator can push the Green button on remote control to switch ON the System. 16 Main characteristics: Alstom Transport
** Is enough just one condition didn't satisfied than the state above mentioned to get Inhibit state of the system Just after green button pushed the system goes in Working on state: 5. Green Light on control panel switch OFF automatically 6. Red light on remote control and control panel switch ON automatically (redundant light signalization) 7. The buzzer is activated automatically for 5 seconds then is stop. By the Working on state the system can returns in the state: 1. Stand by 1a:If the operator push the red button on remote control (Operating condition) 2. Inhibit 2a. if the operator switch off the key on remote control (Operating condition) 2b: if the rapid secure link is disconnecting (Emergency condition) 2c: if the Jupiter plug is disconnected from the vehicle (working condition not foresee) Especially relating to the case 2b, the system is able to actuate a protection in order to interrupt the voltage supply just one instant after the mechanical plugs disconnecting avoiding electric arc and potential injury to the operators. We precise that the case 2c is not a contemplated case over the normal activities of the Operators under High voltage presence. The system even in this case actuates the interruption of Voltage supply. take note that all the protections actuated by the system are simply a primary protection to mitigate all the potential risk of device damaging or injury prevention, Under no circumstances, those protections shall be considered exhaustive to avoid damages to the things or to the worker especially if the workers doesn t respect the right working instruction. 17 Main characteristics: Alstom Transport
To restore Inhibit state from Emergency condition cases 2b-2c, the Operator shall: 3. Turn the Key switch on remote control in position OFF 4. Push the button Red stop on remote control 5. The presence of green light on panel control ON 6. The absence of red light on Panel control and remote control OFF 7. Re connect the rapid secure link or Jupiter plug 8. Please refers to the table here after for component localization and summary working operation: key block button ON button OFF red lamp type green lamp rapid secure link jup iter/shunt regolable buzzer line Contactor control power supply plug interface location remote control remote control remote control remote control + control panel control panel frangible link plug vehicle plug interface control panel control panel control panel vehicle plug interface function without key inserted is not possible to close negative loop circuit of power control -system disabled button pushed in ON - system enable = Key inserted and in position = 1; button pushed in OFF -System interruption - all position of the key HV presence, red light visible directly on remote control by the operator, light on when the KL1 is powered HV absence, green light visible on cabinet, when the KL1 is open and p1 not pushed - pilot pin of frangible, close the negative loop when the frangible plug is completly inserted shunt of jupiter plug metro side, close the negative loop when the movable plug is inserted HV presence, regolable buzzer intermitted sound for 5 seconds, buzzer on when the KL1 is powered power line contactor drived by the logical condition, control unit low voltage power line 48Vdc plug Metro interface 3.5. SOCKET FOR POWER TRANSMISSION TO THE VEHICLE AND RAPID SECURE LINK (ON DEMAND) The socket or plug interface with the vehicle is typically defined by Client or Train integrator who define the type and relevant characteristics. This plug permits the distribution of power supply directly to the vehicle interlocked into a dedicated socket installed from Vehicle side. Please refers to the chapter Technical data hereby about plug characteristics for project. RAPID SECURE LINK (If equipeed) 18 Main characteristics: Alstom Transport
1 The Stinger System is equipped with a secure rapid link for the case of an emergency. If the rail vehicle moves out of the maintenance area, the connection cable is separated at secure link (1), before a high traction force causes a major damage on the Stinger System. If traction force exceeds a certain limit please refer to the Technical data chapter, the secure rapid link disconnects at first the control circuit and then, after a short time, the energy line. This measure prevents building up an electric arc, which can injure personnel. Then both Stinger Systems in the road will be switched OFF. Please refers to the chapter 3.4 to restore Inhibit state ** The Operators mustn t removed, during the normal maintenance activities under High Voltage the rapid secure link or Jupiter plug! 19 Main characteristics: Alstom Transport
4. TECHNICAL DATA Conductor rail Power conductor rail: Number of conductors: Voltage: Continuous rating: 500 A *Control conductor rail: Number of conductors: *Voltage: Continuous rating: Insulating material Protection: Direct contact protection Type Alinox (Al stainless steel) Possibility of different layout 750 VDC 1500 Vdc range 400 A 1300 A Type Alinox (Al stainless steel) Possibility of different layout 24 VDC 110 Vdc ; 48Vac 120 Vac 50hz up to 5,2 A PVC or NORYL -CEI EN60439-2 IP23 EN60529 *The system can produce itself the Voltage to supply Control unit directly from the Power conductor line Collector trolley (including control panel) Collector trolley: hot dip galvanized steel Number of trolleys: 1 Current collectors: 2x 200 A (double collector) for power Number of current collectors: 1 per trolley, possibility of different lay-out Control collectors: 2x 100 A (double collector) for control Number of current collectors: 1 per trolley possibility of different lay-out Voltage: 750 VDC Continuous rating: 300 A per trolley Indication lights: Green Red, Yellow not used, Buzzer (timing adjustable) Weight Control Panel including trolley (Without cables): 30kg Electrical Diagram Cariboni Dwg xxxxx Towing speed: 1.1 m/s (max.) Pull force: 25N? (EHS compliant) Protection: IP 54 Normative: please refers to the electrical diagram of the system Control pendant Pushbuttons: Indicator lamps: Protection: Start Green; Stop Red, security Key switch Red Voltage presence IP65 20 TECHNICAL DATA Alstom Transport
Connection cable Cable type: Ultra flexible unipolar cable 120mm^2 Insulation material: class 5 Number of strands and cross section energy: 4 x 25 mm² Number of strands and cross section control: 2 x 16 mm² Diameter: 23,5 mm Cable length: 8 meter Rapid secure Link Type: Mechanical disconnecting including early Voltage break Connectors Release traction force: 35-40N Material shear rod: xx Length of buffer cable loop: xx Protection: IP55 Vehicle connector Type: FICHE PAT 2621 Souriau (depending of Customer/Train requirement) Park receptacle Type: RECR2621 Souriau (depending of Customer/Train requirement) Environmental conditions Temperature: +3 C to +48 C Humidity: 59% to 90% 21 MAINTENANCE INSTRUCTIONS Alstom Transport
5. MAINTENANCE INSTRUCTIONS a) Insulated conductor rail system for energy supply b) Current collectors Remember to check the recommended torque, reported in this table: Screw/nut Torque Nm M6 8 M8 12 M10 20 M12 40 In order to verify that there are no mistakes in connecting the cables of the power terminals we suggest to check the sequence of the phases. After the installation it is advisable to check the insulation resistance, in order to verify that there aren t components damaged during assembly. MAINTENANCE PROGRAM TO GUARANTEE THE BEST WORKING CONDITIONS WHAT WHEN HOW TO DO CHECKING OF THE WEAR OF THE CONTACT SHOES CHECKING OF THE PRESSURE OF THE CONTACT SHOE CLEANING OF THE SECTIONALIZING JOINTS CHECKING IF THE RAIL EASILY SLIDES INTO THE SUPPORT HANGERS CHECKING OF THE TIGHTENING OF THE FIXING SCREWS OF THE CURRENT COLLECTOR TO THE BRACKET CHECKING OF THE OPENING OF THE EXPANSION JOINT TEST OF THE SLIDING OF THE EXPANSION JOINTS CHECKING OF THE TIGHTENING OF THE JOINT AND FEEDER CLAMPS CHECKING OF THE TIGHTENING OF THE FIXING SCREWS OF THE SUPPORT HANGERS QUARTERLY HALF YEARLY YEARLY SEE POINT "A" SEE POINT "B" SEE POINT "C" SEE POINT "D" SEE POINT "E" SEE POINT "F" SEE POINT "G" SEE POINT "E" SEE POINT "E" A. CONTACT SHOES The contact shoes have to be replaced when the wear has reached the replacing line engraved on one side of the contact shoe. The replacement is made unscrewing the two screws, which tighten the two parts of the insulating shoe-holder, unscrewing the screw, which fixes the cable to the shoe; then remove the worn-out contact shoe and insert the new one as shown in the previous point. B. SPRINGS OF THE CURRENT COLLECTORS The springs have to be replaced when the pressure in working conditions is lower than 2 Kg. C. PERIODIC CLEANING OF THE LINE Remove eventual deposits of dust, grease or other, that may be present on the insulating housing of the rail, the support hangers or the current collectors, which could reduce the insulation distances. D. PERIODIC CLEANING OF THE SLIDING AREAS Remove eventual deposits of dust, grease or other, that may be present on the insulating housing of the rail, which could prevent the free sliding of the rail into the support hangers during the expansion; the same for the contact shoe sliding area. E. TIGHTENING OF THE SCREWS Check the tightening of the various screws by a dynamometric wrench rated to the suggested values (M10 20Nm, M12 40 Nm ) 22 MAINTENANCE INSTRUCTIONS Alstom Transport