Pantograph 25 kv TSG15B 1
1 Purpose / function The pantograph is articulated machine system, which install in roof of locomomtive with insulators. It maintains the power supply from an overhead line on electrically driven vehicles by roof current shunts when the collector head of pantograph raises to contact catenary. 2 Description Figure 1 Pantograph overview At the single-arm-pantograph the collector-head is guided vertically by an articulated system, which forms a four-link-system. Due to the vertical movement of the collector-head the direction of movement has no influence on the contact force, the pantograph is suitable for theuse in both directions as well. The collector head with the collector-strips should be situated as close as possible over a bogie-pivot or over a leading wheelset. As the air pressure within the air bellows increases to the value supplied by regulator, the pantograph gradually raises and the contact force FK against the overhead wire is established. 2
Lowering of the pantograph is maintained by its own weight, by discharging the compressed air. An insulating hose performs the air supply of the whole compressed air-system. 2.1 Technical data 2.1.1 Pantograph 8WL0 127-6YH69 minimum height with support insulators (in housed pos., from roof to coll.strips) 670 +8/-10 mm minimum working height from lowered position 220 mm maximum working height from lowered position 2250 mm maximum raising height working height from lowered position >2500 mm maximum length of collector head 1950 ±10 mm Rated Current 1000 A Contact force total, static 70 N adjustable, max. Contact force 150 N Rated speed on catenary overhead line(equal to DB - Type Re250) 200 km/h lateral deflection at 1,5 m raising height (with lateral force applied 100 N)<10 mm Mass pantograph,complete (without support insulators)<110 kg Compressed air - rated pressure ca. 5,5 bar Maximum working pressure 10,0 bar Lowering time from max. raising height 6 sec Raising time to maximum raising height 6-10 sec Insutallation size 1100 800mm Air duct interface G1/4 2.1.2 Collector head Framed collector head with rubber - torsion - element suspension Contact strips 2 Pcs. Spring rate of the pan suspension at working pointprogressive c=8800±10%n/m Maximum width over horns 1950 ±10 mm Collector strip - mid distance 330 ±3 mm 2.1.3 Contact strip Contact strip length (Carbon) Carbon dimensions (Width x Height) Materials, Contact strip Bearer (with ADD equipped) 34.5 x 22 mm 1250 mm Graphite-Carbon Aluminium 2.1.4 25KV Support insulators Nominal voltage 25 kv Height 400mm Weight 7.357 kg 3
2.1.5 Insulating hose Nominalvoltage:25 kv Length:1220 mm Diameter of air connection G1/4" female Materia Hose:Teflon Terminals:Steel,zinc coated Compressed-air :rated pressure 5.5 bar burst test pressure:12 bar 2.2 Technical description The single-arm-pantograph is arranged from the following main parts: 2.2.1 Base frame Description: Figure 3 Base frame The base frame is built up of square steel tubes, tightly welded on the seal edges. It consists of the bearing brackets for the lower arm and the coupling rod and for the system damper, the supports for the air bellows and a sprung support for upper arm and collector head. For mounting the base frame on the support insulators there are brackets with bores of diameter 24 for screws M20. For the current connection there are holes with a diameter of 14 in both brackets provided. This brackets are made of stainless steel. 2.2.2 Support insulators Nominal voltage 25 kv Height 400mm Weight 7.357 kg 4
2.2.3 Articulated system The articulated system consists of the lower arm, the upper arm and the coupling rod. Together with the base frame these parts form an articulated square, on which the apex point of the upper arm follows a nearly vertical straight line. 2.2.4 Current shunts, flexible The current flowing over the pantograph passes by the roller bearings and the insulating spring elements of the collector head suspension through highly flexible shunts. 2.2.5 Collector head The collector head is the immediate contact element to the overhead line. It runs directly on the overhead line and is designed for as low unsprung mass as possible. Against the articulated system the collector head is uncoupled by the collector head suspension. The collector head has two contact strips. 2.2.6 Actuating, air bellow lifting device On this pantograph the necessary torque for raising and for establishing the required contact force is applied by two air bellows filled with compressed air, whereby the force of the drive actuates via ropes and curved segments on the lower arm. A highly sensitive regulating valve, which is mounted at the valve panel, controls the necessary air pressure with an accuracy of ±0,01 bar. The necessary contact force can be adjusted easily by varying the air pressure. 2.2.7 System damper To damp out undesired movements of the pantograph, stimulated from the overhead line i.e.by a second pantograph at multiple traction, a damper between lower arm and base frame is provided. 2.2.8 Automatic lowering device To keep damage to the drive wire and pantograph caused by excessively worn or damaged/broken off carbon pieces to a minimum, the pantograph is equipped with a pneumatic monitoring system. There are special carbon strips used for this purpose. A piping over the lower arm and the upper arm connects the carbon strips with a valve group, which is mounted at the basic frame. 2.2.9 Valve panel All necessary valves, throttles, a water separator with air-filter and a pressure switch are assembled are assembled at a valve panel inside of the loco. The connection to the air bellows compressed air had to be dry and clean(refer to figure 6). 3 Safety instructions The pantograph links the overhead - line with the electrical equipment of the 5
vehicle. Therefore during normal operation the pantograph is under high tension of 25 000 V. Any contacts with the pantograph or other live parts of the roof equipment under this condition will cause lethal injuries. Before doing any work on the pantograph or other parts of the roof equipment make sure that the vehicle is not under live wire. If possible do maintenance and repair in a workshop without overhead line. If not, first check clearance and grounding of the overhead wire in front and behind the vehicle in accordance with the rules of the railway company! 4 Instruction manual The pantograph is raised by selecting the pantograph control switch or button in the drivers cab in to the UP-position. This causes the pantograph magnet valve VE (part of the pneumatic system of the locomotive) to energize, allowing compressed air to enter the valve panel. The air flows via the valve panel (inside the loco), by piping and an insulating hose (connection between locomotive outlet and pantograph connection) to the pantograph. 4.1 Operation Table 4.1 Operation No.. Components Measures Effect / Indicator Valve panel Valve panel Valve panel 3.8~4.0 bar Put R (prec.pressure reg.valve) - ca.3.8~4.0 bar DRH Adjust DRH DRS Adjust DRS Display (pressure gauge ) -ca.3.8~4.0bar Display stopwatch: 6~10 second Display stopwatch: 6 second 5 Assembly and commissioning 5.1 Transportation / shipment / storage 5.1.1 Transportation / shipment The transportation of the pantograph has to be done in such a way that no part of the pantograph, especially the collector head or the upper arm will be damaged. For transportation bind down the apex tube of the upper arm to the base frame. For transportation over longer distances by train or truck each pantograph should be packed separately in a box or on a transportation rack. The dimension of wood box is 2510 2010 450mm. 6
5.1.2 Storage The pantograph has to be laid on a suitable support, like a rack or pieces of wood, therefore the pantograph should lie only on the base frame and no part of the system should touch the ground. 5.2 Installation Fall protection safety equipment (e.g. safety belts) must be used. However, movable platforms are better. The train must be isolated from pantograph line as described in the maintenance manual Isolate the Train from Power Supply. The train must be isolated from the auxiliary power supply as described in the maintenance manual Isolate the Train from Power Supply. The train must be deactivated as described in the maintenance manual MM 0002 Isolate the Train from Power Supply. Before working on the roof, the overhead line must be deactivated, connected to the ground, and secured against unauthorized activation! Additionally, all relevant local regulations must be followed. 5.4 Maintenance 5.4.1 Maintenance steps Maintenance stage (km) Table 5.4.1 Maintenance steps for Project China Sprinter Description Running performance Interval (Period) VI Visual inspection 10.000 km 2 weeks I1 Inspection 1 100.000 km 6 month I2 Inspection 2 200.000 km 1 year I3 Inspection 3 400.000 km 2 year R1 Revision 1 800.000 km 1.200.000 km R2 Revision 2 1.600.000 km 2.400.000 km R3 Revison 3 3.200.000 km 3.600.000 km UM Unscheduled maintenance 4 6 years 8 12years 16 18years 7
5.4.2 Maintenance works Safety Instructions Fall protection safety equipment (e.g. safety belts) must be used. However, movable platforms are better. The train must be isolated from pantograph line as described in the maintenance manual Isolate the Train from Power Supply. The train must be isolated from the auxiliary power supply as described in the maintenance manual Isolate the Train from Power Supply. The train must be deactivated as described in the maintenance manual MM 0002 Isolate the Train from Power Supply. Before working on the roof, the overhead line must be deactivated, connected to the ground, and secured against unauthorized activation! Additionally, all relevant local regulations must be followed. Never lift the pantograph manually at the collector head while the pantograph is in lowest position! 8