Ctel Sie Elt CLP Man 52907 - 01

EJECUCION DE LAS OBRAS CIVILES Y
ELECTROMECANICAS DEL SISTEMA ELECTRICO DE

TRANSPORTE MASIVO DE LIMA Y CALLAO
LINEA 1 : TRAMO VILLA EL SALVADOR- AVENIDA GRAU

________________
01 07-NOV-11 APROBADO PARA CONSTRUCCIÓN SIE MPE SPD
0A 10-AGO-11 EMITIDO PARA REVISIÓN SIE MPE SPD
Rev. Fecha Descripción de la revisión Preparado por Revisado por Aprobado por
dd-mmm-aa Visa Visa Visa
PROPIETARIO: CONTRATISTA:
Este documento es propiedad de Consorcio Tren Eléctrico Lima. Este documento no puede ser copiado o transmitido a
terceros sin autorización previa.
Tipo de Documento :
MANUAL
Identificación de la documentación: Estado :

C T E L S I E E L T C L P M A N 5 2 9 0 7 0 1 APC
Título del Documento:
Manual de Operación y Mantenimiento

de Catenarias
Ref.: 5,02 (05.03/05.04)
Supervisión: Aprobado sin comentarios Cód. 1 Firma: Página:
Aprobado con comentarios Cód. 2 1/50

Revisar y reenviar Cód. 3
EJECUCION DE LAS OBRAS CIVILES Y Doc. N°:
ELECTROMECANICAS DEL SISTEMA ELECTRICO DE CTEL-SIE-ELT-CLP-MAN-52907
Rev.: 01 Fecha: 07-NOV-11
MANUAL DE OPERACIÓN Y MANTENIMIENTO
DE CATENARIAS Pagina: 2/50
HOJA DE REVISION
Rev. N° Estado Descripción de la Revisión
0A EPR EMITIDO PARA REVISIÓN
01 APC APROBADO PARA CONSTRUCCIÓN

INDICE
HOJA DE REVISION.......................................................................................................................................... 2
INDICE ................................................................................................................................................................ 3
1. ALCANCES Y PROPOSITO ...................................................................................................................... 5
2. DOCUMENTOS DE REFERENCIA............................................................................................................ 5
3. DEFINICIONES........................................................................................................................................... 5
4. ABREVIATURAS........................................................................................................................................ 6
5. REGLAS DE SEGURIDAD GENERALES ................................................................................................. 6

5.1 EL MANEJO DEL TREN .......................................................................................................................... 6
5.2 TENSIÓN ELÉCTRICA............................................................................................................................ 7
5.3 PUESTA A TIERRA ................................................................................................................................ 7
5.4 TRABAJO EN ALTURAS ......................................................................................................................... 8
6. DESCRIPCION GENERAL ........................................................................................................................ 8

6.1 FUNCIÓN DE LA CATENARIA DENTRO DEL SISTEMA ELÉCTRICO ............................................................... 8
6.2 DISTRIBUCIÓN DEL SUMINISTRO ELÉCTRICO EN LA CATENARIA ............................................................... 9
6.3 PANTOGRAFO ...................................................................................................................................10
7. HILOS DE CONTACTO Y CABLES ......................................................................................................11

7.1 LUGAR DE MONTAJE ..........................................................................................................................11
7.2 DESCRIPCIÓN Y DATOS TÉCNICOS .....................................................................................................11
7.2.1 Cable Mensajero. ...............................................................................................................11
7.2.2 Hilo de Contacto. ...............................................................................................................11
7.2.3 Péndolas. ...........................................................................................................................11
7.3 MANTENIMIENTO ...............................................................................................................................18
7.3.1 Paso por agujas .................................................................................................................20
7.3.2 Zigzag ................................................................................................................................20
7.3.3 Altura del hilo de contacto .................................................................................................21
7.3.4 Aproximaciones peligrosas ................................................................................................21
7.3.5 Torsión en el hilo de contacto ............................................................................................21
7.3.6 Fricción del hilo de contacto ..............................................................................................21
7.4 REPARACIÓN ....................................................................................................................................22
7.4.1 Cambio de un trecho corto de hilo de contacto .................................................................22
7.4.2 Cambio de la totalidad del hilo de contacto en un vano ....................................................27
7.4.3 Reparación de una rotura en el cable mensajero..............................................................35
7.4.4 Reparación del cable mensajero doble, cuando se han roto simultáneamente
ambos cables mensajeros. ................................................................................................37
7.4.5 Péndola provisional............................................................................................................38
7.4.6 Péndolas ............................................................................................................................39
7.4.7 Comprobación y visto bueno .............................................................................................40
8. BRAZOS (MENSULAS) ...........................................................................................................................41

8.1 LUGAR DE MONTAJE: .........................................................................................................................41

8.2 DESCRIPCIÓN Y DATOS TÉCNICOS ......................................................................................................41
8.3 MANTENIMIENTO ...............................................................................................................................44
8.4 REPARACIÓN ....................................................................................................................................44
8.4.1 Modificación de la longitud del cable mensajero y del hilo de contacto ............................44
8.4.2 Cambio de aisladores ........................................................................................................47
8.4.3 Comprobación y visto bueno .............................................................................................47
ANEXO A: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE LOS SECCIONADORES ........................48
ANEXO B: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE AISLADORES DE SECCIÓN .................49
ANEXO C: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE POLEAS ..................................................50

1. ALCANCES Y PROPOSITO
El presente manual describe los procedimientos de operación y mantenimiento necesarios para el

funcionamiento de la Catenaria instalada por Siemens en la Prolongación de línea 1 del Tren Eléctrico
de Lima bajo el contrato CTEL-E&M-GC-001-2010, basado en la experiencia acumulada durante
décadas por Siemens en instalaciones de catenarias y se apoya en la práctica de mantenimiento y
reparación de numerosas fallas en empresas de transporte.
No se pretende reemplazar o influenciar las normas nacionales, regionales o internas vigentes.
El sentido del mantenimiento es evitar lo más posible las fallas en la instalación.
2. DOCUMENTOS DE REFERENCIA
CTEL-SIE-ELT-CLP-PRG-52738 Plan de Capacitación - Sistema de Catenarias
3. DEFINICIONES
Término Definición
Capacitación Entrenamiento
Contratista Siemens
Contrato Se refiere a los Documentos Principal y Complementarios, así como a los
addenda del Contrato CTEL-E&M-GC-001-2010
Entrenador Personal del cliente que realizarán el entrenamiento teórico y participarán o
realizarán el entrenamiento práctico según sea requerido
Entrenador Experto Los Entrenadores expertos realizan el entrenamiento del Personal Clave.
Entrenamiento Capacitación
Mantenimiento Combinación de actividades técnicas y organizacionales necesarias para
mantener un sistema en operación
Operar Manejo de los equipos
Personal Base Personal que desempeñará los Puestos de Trabajo requeridos para la
Operación y Mantenimiento del TREN ELECTRICO, a excepción de los
gerenciales
Personal Clave Personal del cliente adiestrado para que posteriormente entrene al Personal
Base y así multiplicar el proceso de adiestramiento.
El Personal Clave estará altamente calificado para futuras posiciones
gerenciales, con conocimientos de la tecnología y de los sistemas de operación.
4. ABREVIATURAS
Término Description (English) Descripción (Español)

AT High Tension Alta Tensión
BT Low Tension Baja Tensión
CTEL Consorcio Tren Eléctrico de Lima Consorcio Tren Eléctrico de Lima
MT Medium Tension Media Tensión
O&M Operation and Maintenance Operación y Mantenimiento
OCS Over Head Catenary System Sistema de Catenarias
ONC Pre Revenue Service Operación No Comercial
OOCC Civil Work Obra Civil
PSY Power Supply Suministro de Energía
PYT Depot and Workshop Equipment Patio y Talleres
SCADA Sistema de Control a Distancia
LAC Over head Catenary Systems Línea Aérea de contacto
SSAC Siemens Siemens
TRW Track work Vía Férrea
5. REGLAS DE SEGURIDAD GENERALES
Las presentes reglas de seguridad no anulan o modifican las normas vigentes.

Las indicaciones aquí presentadas pretenden más bien transmitir los conocimientos y experiencias en el
campo de la previsión de accidentes adquiridas en el montaje de instalaciones de catenarias de todo
tipo.
Los accidentes en la construcción de catenarias tienen diversas causas entre las cuales sobresalen las
siguientes tres:
a) El manejo del tren.
b) Trabajos en la cercanía de partes de la instalación que se encuentran bajo tensión eléctrica.
c) El trabajo en las alturas.
5.1 EL MANEJO DEL TREN

Deben tenerse en cuenta las siguientes reglas básicas:
a) No trabajar en tramos de la vía transitables sin la presencia de vigilantes
b) Las señales de precaución emitidas por los vigilantes deben ser reconocibles aun
estando en servicio los aparatos de trabajo (p. Ej., máquinas de montaje)
c) Al trabajar en las zonas de las vías deben emplearse ropas llamativas indicadoras de
peligro
d) No se deben depositar sobre las vías los materiales de construcción.
5.2 TENSIÓN ELÉCTRICA

No trabajar jamás en las instalaciones de la catenaria sin antes haberlas desconectado de forma
confiable y haberlas puesto a tierra.
PELIGRO
El no atenerse a las normas de
seguridad puede causar la
muerte del personal que esté
trabajando en la catenaria, o que
vaya a trabajar en está.
5.3 PUESTA A TIERRA

Para colocar la puesta a tierra ha de seguirse rigurosamente la siguiente secuencia:
a) Desenergizar
b) Asegurar contra la reconexión
c) Para esto se asegura en primer lugar la borna de conexión a los rieles de la barra de
puesta a tierra fijándola al riel de tierra y luego se toca con la punta de la barra uno de
los brazos.
d) Colgar la barra de puesta a tierra en el hilo de contacto.
e) Al retirar la puesta a tierra es indispensable seguir la secuencia indicada en el sentido
contrario, es decir, descolgar primero la barra de puesta a tierra y liberar luego la borna
de conexión a los rieles.
Figura 01. Barra de Puesta a Tierra
5.4 TRABAJO EN ALTURAS

Trabajar siempre con el equipo de protección necesario, es decir, el cinturón de seguridad,
zapatos de seguridad y casco protector. No mover ninguno de los vehículos ó escalera sin haber
recibido la orden correspondiente. Recostar las escaleras de mano únicamente en puntos de
apoyo seguros y asegurarlas contra resbalones.
6. DESCRIPCION GENERAL
6.1 FUNCIÓN DE LA CATENARIA DENTRO DEL SISTEMA ELÉCTRICO

La catenaria es un componente del circuito de corriente, el cual está constituido como sigue:
La subestación, el cable, la catenaria, el pantógrafo, la tracción del vehículo.
Figura 02. La Catenaria como parte del Circuito de Corriente
El hilo de contacto se tiende de tal manera que se garantiza el contacto eléctrico entre éste y las
varillas de contacto del pantógrafo.
El aislamiento se ha diseñado para la tensión nominal de 1500 V y considerando las condiciones

agravantes adicionales en alturas grandes. Al aumentar la altura sobre el nivel del mar se reduce
el poder aislante del aire debido a las modificaciones en su densidad.
El aislamiento se llevó a cabo en los trayectos de vía de forma doble y en la zona de depósitos
en forma sencilla.
Para el dimensionamiento de los componentes y los mástiles se tuvo en cuenta que Lima se
encuentra localizado en una zona afectada por movimientos telúricos.
Los detalles técnicos de la catenaria pueden tomarse del expediente técnico correspondiente.
6.2 DISTRIBUCIÓN DEL SUMINISTRO ELÉCTRICO EN LA CATENARIA

La catenaria está dividida en numerosas secciones eléctricas, las cuales están aisladas entre si.
En condiciones normales de servicio, estas secciones están conectadas por medio de los
seccionadores dispuestos en subestaciones y mástiles. La figura 03 muestra las secciones
eléctricas entre EAT y EGR.
Figura 03. Esquema de Distribución de Vanos de Catenaria Lineas Principales.
6.3 PANTOGRAFO
El pantógrafo del vehículo de pasajeros (figura 04) consta de un bastidor basculante porta
contactos, el cual está dotado de varillas de contacto. El hilo de contacto, cuando se ha tendido
correctamente, se encuentra sobre las varillas de contacto y no alcanza las zonas de
emergencia. Esto tiene que ser así aun en alta velocidad y en los movimientos de oscilación
producidos en el vehículo cuando circula a dicha velocidad. El estado de las varillas de contacto
(zona de frotación) es una buena referencia para el tendido correcto del hilo de contacto. La zona
de emergencia debe permanecer intacta. Las varillas de contacto deben estar desgastadas
uniformemente a todo lo ancho. Esto significa que el zigzag se emplea correctamente.
Figura 04. Pantografo.

7. HILOS DE CONTACTO Y CABLES
7.1 LUGAR DE MONTAJE

Sobre toda la vía principal, así como en Patio y Taller
7.2 DESCRIPCIÓN Y DATOS TÉCNICOS

La catenaria Fig. 05 se compone de:
Figura 05. Catenaria
7.2.1 Cable Mensajero.

Estos son 2 cables de cobre de 120 mm² de sección de 19 hilos.
7.2.2 Hilo de Contacto.

Este es un cable ranurado Ri100 de cobre con una sección transversal de 100mm².
7.2.3 Péndolas.
Las péndolas (Fig. 06 y 07) están hechas de cable flexible de bronce con una sección de
25mm2, 133 hilos.
Las péndolas sirven para colgar el hilo de contacto del cable sustentador y así mantener
el hilo de contacto en la altura correcta. Además conducen corrientes de igualación entre
el cable mensajero y el hilo de contacto.
Para su colocación se aprisionan los extremos con un terminal de cable y se aseguran

mediante una caballete.
Las péndolas externas dentro de un vano se sitúan a 5 m, a la derecha e izquierda, del

punto de apoyo. El espacio entre estas péndolas se divide en distancias iguales cuya
longitud ha de ser menor o igual a 11 m. Ver Fig. 2,1-5. Las longitudes de las péndolas
se encuentran en tablas líneas debajo de esta misma sección.
En curvas de la vía y en vanos más largos, se desplaza el hilo de contacto en los puntos
de apoyo (brazos o pórticos flexibles), con respecto al centro de la vía. Este
desplazamiento se conoce como Zig-Zag, el cual tiene la misión de producir un desgaste
uniforme de las varillas de contacto del pantógrafo, sin que el hilo de contacto se salga
de ellas. La figura 08 muestra las consideraciones teóricas.
El hilo de contacto debe encontrarse siempre sobre las varillas de contacto. En los
puntos de apoyo la posición del hilo de contacto está fijada por el brazo de atirantado,
por ello se puede modificar muy poco.
Por el contrario, en el centro del vano, el viento lateral puede sacar el hilo de contacto del
pantógrafo, y esto con mayor razón cuanto más largo sea el vano. Por lo tanto, el hilo de
contacto debe permanecer lo más cerca posible del centro de la vía, más cerca cuanto
más largo sea el vano.
La catenaria para el Patio y Taller está dotada únicamente con un cable sustentador y un
hilo de contacto. Aparte de esto, es idéntica a la catenaria con 2 cables mensajeros
como se acabó de describir.
Figura 06. Péndola para Cable Sustentador Sencillo
Figura 07. Pendola para Cable Sustentador Doble

Distancia : Mástil - péndola Distancia entre mástiles

Distancia : Péndola - péndola Distancia péndola . mástil
Distancia : Cable - hilo de contacto
No de péndola 1 2 3 4 5 6 7 8
5.00 15.00 20.00
5.00 10.00 5.00
1.135 1.135
5.00 16.00 21.00

5.00 11.00 5.00
1.131 1.131
5.00 11.00 22.00

5.00 6.00 5.00
1.126 1.098
5.00 11.50 18.00 23.00

5.00 6.50 6.50 5.00
1.122 1.089 1.122
5.00 12.00 19.00 24.00

5.00 7.00 7.00 5.00
1.119 1.080 1.119
5.00 12.50 20.00 25.00

5.00 7.50 7.50 5.00
1.115 1.070 1.115
5.00 13.00 21.00 26.00

5.00 8.00 8.00 5.00
1.111 1.060 1.111
5.00 13.50 22.00 27.00

5.00 8.50 8.50 5.00
1.107 1.050 1.107
5.00 14.00 23.00 28.00

5.00 9.00 9.00 5.00
1.103 1.039 1.103
5.00 14.50 24.00 29.00

5.00 9.50 9.50 5.00
1.099 1.028 1.099
5.00 15.00 25.00 30.00

5.00 10.00 10.00 5.00
1.095 1.016 1.095
5.00 15.50 26.00 31.00

5.00 10.50 10.50 5.00
1.091 1.004 1.091
5.00 16.00 27.00 32.00

5.00 11.00 11.00 5.00
1.087 0.992 1.087
5.00 12.67 20.33 28.00 33.00

5.00 7.67 7.67 7.67 5.00
1.083 0.990 0.990 1.083
5.00 13.00 21.00 29.00 33.00

5.00 8.00 8.00 8.00 5.00
1.079 0.978 0.978 1.079
5.00 13.33 21.67 30.00 35.00

5.00 8.33 8.33 8.33 5.00
1.075 0.965 0.965 1.075
5.00 13.67 22.33 31.00 36.00

5.00 8.67 8.67 8.67 5.00
1.071 0.953 0.953 1.071
5.00 14.00 23.00 32.00 37.00

5.00 9.00 9.00 9.00 5.00
1.067 0.939 0.939 1.067

No de péndola 1 2 3 4 5 6 7 8
5.00 14.33 23.67 33.00 38.00
5.00 9.33 9.33 9.33 5.00
1.063 0.926 0.926 .063
5.00 14.67 24.33 34.00 39.00

5.00 9.67 9.67 9.67 5.00
1.060 0.912 0.912 1.060
5.00 15.00 25.00 35.00 40.00

5.00 10.00 10.00 10.00 5.00
1.056 0.898 0.898 1.056
5.00 15.33 25.67 36.00 41.00

5.00 10.33 10.33 10.33 5.00
1.052 0.883 0.883 1.052
5.00 15.67 26.33 37.00 42.00

5.00 10.67 10.67 10.67 5.00
1.048 0.869 0.869 1.048
5.00 16.00 27.00 38.00 43.00

5.00 11.00 11.00 11.00 5.00
1.044 0.853 0.853 1.044
5.00 13.50 22.00 30.50 39.00 44.00

5.00 8.50 8.50 8.50 8.50 5.00
1.040 0.902 0.856 0.902 1.040
5.00 13.75 22.50 31.25 40.00 45.00

5.00 8.75 8.75 8.75 8.75 5.00
1.036 0.888 0.839 0.888 1.036
5.00 14.00 23.00 32.00 41.00 46.00

5.00 9.00 9.00 9.00 9.00 5.00
1.032 0.874 0.821 0.874 1.032
5.00 14.25 23.50 32.75 42.00 47.00

5.00 9.25 9.25 9.25 9.25 5.00
1.028 0.859 0.803 0.859 1.028
5.00 14.50 24.00 33.50 43.00 48.00

5.00 9.50 9.50 9.50 9.50 5.00
1.024 0.844 0.784 0.844 1.024
5.00 14.75 24.50 34.25 44.00 49.00

5.00 9.75 9.75 9.75 9.75 5.00
1.020 0.829 0.765 0.829 1.020
5.00 15.00 25.00 35.00 45.00 50.00

5.00 10.00 10.00 10.00 10.00 5.00
1.016 0.813 0.746 0.813 1.016
5.00 15.25 25.50 35.75 46.00 51.00

5.00 10.25 10.25 10.25 10.25 5.00
1.012 0.798 0.726 0.798 1.012
5.00 15.50 26.00 36.50 47.00 52.00

5.00 10.50 10.50 10.50 10.50 5.00
1.008 0.782 0.706 0.782 1.008
5.00 15.75 26.50 37.25 48.00 53.00

5.00 10.75 10.75 10.75 10.75 5.00
1.005 0.765 0.685 0.765 1.005
5.00 16.00 27.00 38.00 49.00 54.00

5.00 11.00 11.00 11.00 11.00 5.00
1.001 0.748 0.644 0.748 1.001
5.00 14.00 23.00 32.00 41.00 50.00 55.00

5.00 9.00 9.00 9.00 9.00 9.00 5.00
0.996 0.769 0.656 0.656 0.769 0.996

No de péndola 1 2 3 4 5 6 7 8
5.00 14.20 23.40 32.60 41.80 51.00 56.00
5.00 9.20 9.20 9.20 9.20 9.20 5.00
0.992 0.754 0.635 0.635 0.754 0.992
5.00 14.40 23.80 33.20 42.60 52.00 57.00

5.00 9.40 9.40 9.40 9.40 9.40 5.00
0.989 0.738 0.613 0.613 0.738 0.989
5.00 14.60 24.20 33.80 43.40 53.00 58.00

5.00 9.60 9.60 9.60 9.60 9.60 5.00
0.985 0.723 0.592 0.592 0.723 0.985
5.00 14.80 24.60 34.40 44.20 54.00 59.00

5.00 9.80 9.80 9.80 9.80 9.80 5.00
0.981 0.707 0.570 0.570 0.707 0.981
5.00 15.00 25.00 35.00 45.00 55.00 60.00

5.00 10.00 10.00 10.00 10.00 10.00 5.00
0.977 0.690 0.547 0.547 0.690 0.977
5.00 15.20 25.40 35.60 45.80 56.00 61.00

5.00 10.20 10.20 10.20 10.20 10.20 5.00
0.973 0.674 0.524 0.524 0.674 0.973
5.00 15.40 25.80 36.20 46.60 57.00 62.00

5.00 10.40 10.40 10.40 10.40 10.40 5.00
0.969 0.657 0.501 0.501 0.657 0.969
5.00 15.60 26.20 36.80 47.40 58.00 63.00

5.00 10.60 10.60 10.60 10.60 10.60 5.00
0.965 0.640 0.477 0.477 0.640 0.965
5.00 15.80 26.60 37.40 48.20 59.00 64.00

5.00 10.80 10.80 10.80 10.80 10.80 5.00
0.961 0.623 0.453 0.453 0.623 0.961
5.00 16.00 27.00 38.00 49.00 60.00 65.00

5.00 11.00 11.00 11.00 11.00 11.00 5.00
0.957 0.605 0.429 0.429 0.605 0.957
5.00 14.33 23.67 33.00 42.33 51.67 61.00 66.00

5.00 9.33 9.33 9.33 9.33 9.33 9.33 5.00
1.953 0.635 0.443 0.380 0.443 0.635 0.953
5.00 14.50 24.00 33.50 43.00 52.50 62.00 67.00

5.00 9.50 9.50 9.50 9.50 9.50 9.50 5.00
0.949 0.618 0.420 0.354 0.420 0.618 0.949
5.00 14.67 24.33 34.00 43.67 53.33 63.00 68.00

5.00 9.67 9.67 9.67 9.67 9.67 9.67 5.00
0.945 0.602 0.396 0.327 0.396 0.602 0.945
5.00 14.83 24.67 34.50 44.33 54.17 64.00 69.00

5.00 9.83 9.83 9.83 9.83 9.83 9.83 5.00
0.941 0.585 0.372 0.301 0.372 0.585 0.941
5.00 15.00 25.00 35.00 45.00 55.00 65.00 70.00

5.00 10.00 10.00 10.00 10.00 10.00 10.00 5.00
0.938 0.569 0.347 0.273 0.347 0.569 0.938
5.00 15.17 25.33 35.30 45.67 55.83 66.00 71.00

5.00 10.17 10.17 10.17 10.17 10.17 10.17 5.00
0.934 0.552 0.322 0.246 0.322 0.552 0.934
5.00 15.33 25.67 36.00 46.33 56.67 67.00 72.00

5.00 10.33 10.33 10.33 10.33 10.33 10.33 5.00
0.930 0.534 0.297 0.218 0.297 0.534 0.930
Figura 08. Desplazamiento del Hilo de Contacto en Puntos de Apoyo

7.3 M ANTENIMIENTO
Los cables sustentadores, hilos de contacto y péndolas deben inspeccionarse cada seis meses.
PELIGRO
Antes de realizar cualquier tipo de
mantenimiento o reparación en la
catenaria, asegurarse de que ha sido
cortado el suministro de corriente y de
que el hilo de contacto está puesto a
tierra a ambos lados del punto de
reparación
Existen diferentes tipos de fallas que se detectan directamente en el pantógrafo del tren, por
ejemplo: si se han roto los cantos de las varillas de contacto, o estas dan muestras de deterioro,
estrías o surcos en el grafito de las varillas de contacto indican que los aisladores de sección
están mal ajustados.
Una manera de detectar fallas es realizando viajes de prueba, los cuales permiten tener un mejor
acceso visual al sistema.
Para el viaje de prueba se requiere un vehículo, figura 09, con tracción independiente de la
corriente de la catenaria y con una plataforma cuya altura se pueda modificar. La plataforma
debe poder transportar 4 personas con herramientas y estar dotada de una barandilla
desmontable. Se necesita un sistema de comunicación entre la cabina del conductor y la
plataforma. Debe ser posible detener el vehículo desde la plataforma.
El vehículo con plataforma está equipado con un pantógrafo de pruebas, que sólo se emplea
para simular el comportamiento dinámico durante la marcha del pantógrafo del vehículo de
pasajeros. El pantógrafo de pruebas es un instrumento importante para comprobar el estado de
la catenaria.
Figura 09. Vehiculo de Mantenimiento con Plataforma de Elevación
Al comienzo del viaje de prueba, se sitúa el personal de mantenimiento sobre la plataforma de

elevación teniendo a mano los planos de localización de las secciones a recorrer, para poder
orientarse. Se recomienda anotar las medidas para poder hacer comparaciones más tarde.
El pantógrafo de pruebas se levanta y se pone en contacto con la catenaria. Ajustar la presión

del pantógrafo de pruebas contra el hilo de contacto en 1,5 ó 2 veces la presión normal. La
presión del pantógrafo de pruebas contra el hilo de contacto en estado de reposo es de 85 N y
aumenta a 105 N con una velocidad de 70 km/h.
Iniciar el viaje de prueba. Durante el viaje de prueba, el personal de mantenimiento ha de

observar el hilo de contacto sobre las varillas de contacto. La velocidad de marcha no debe ser
mayor que la de una persona caminando.
ATENCION
El pantógrafo de pruebas debe encontrarse siempre delante del
observador, visto en la dirección de marcha. Si el observador se ve
obligado, durante el viaje, a mirar hacia atrás, hay un gran peligro de
accidente, ya que puede golpearse la cabeza con brazos o pórticos.
Eventualmente deberá darse vuelta al vehículo previamente en el
lazo del depósito.
Observando el desplazamiento del pantógrafo de pruebas se pueden reconocer las fallas

posibles, que se explican a continuación:
7.3.1 Paso por agujas

El hilo de contacto que en un grupo de agujas se desplaza lateralmente, debe quedar
claramente en la zona de emergencia del pantógrafo, de lo contrario existe el peligro de
que el hilo de contacto se enganche por debajo de dicha zona de seguridad. No
obstante, con la presión del pantógrafo de pruebas elevada (1,5 a 2 veces), el hilo de
contacto puede llegar a tocar la zona de emergencia.
7.3.2 Zigzag
Se debe marcar en el pantógrafo de pruebas el valor máximo del zigzag (20 ó 25 cm a la
izquierda y derecha del centro del pantógrafo de pruebas). Así, durante el viaje de
prueba, puede controlarse el zigzag en cada uno de los puntos de contacto.
Deben observarse las siguientes influencias, que pueden alterar las mediciones:
a) El pantógrafo de pruebas no está montado exactamente en el centro.
b) El vehículo de plataforma cuelga hacia un lado. Esto ocurre especialmente en

curvas que tienen un peralte de vía muy fuerte, donde la amortiguación del
vagón cede más hacia un lado.
c) El brazo de atirantado se ha desplazado a consecuencia del deslizamiento
longitudinal del hilo de contacto. Este deslizamiento es un proceso normal,
ocasionado por los cambios de temperatura y las secciones de tensionamiento
móviles.
7.3.3 Altura del hilo de contacto

La medición se puede realizar con una escala de alturas, agregada al pantógrafo de
pruebas, o mediante la utilización de un medidor de distancia laser.
7.3.4 Aproximaciones peligrosas

Todas las partes que se encuentran bajo tensión eléctrica deben tener una separación
mínima por aire de las partes que se encuentran puestas a tierra. Estos son los valores
mínimos:
- Estáticos 100 mm (en reposo)
- Dinámicos 80 mm (mientras el pantógrafo se mueve, durante el viaje)
Las zonas críticas, por ejemplo el cable sustentador debajo de un puente, se deben
medir con las dimensiones de vehículo de plataforma en reposo.
7.3.5 Torsión en el hilo de contacto

Si los caballetes para el hilo de contacto están inclinados, puede suceder que el
caballete golpee con el grafito de las varillas de contacto y rompa los cantos de estas. La
causa de esta inclinación es una torsión en el hilo de contacto.
7.3.6 Fricción del hilo de contacto

El pantógrafo está dotado de varillas de contacto para mantener la fricción del hilo de
contacto, Fig. 2,1-9, lo más reducida posible. Sin embargo, el hilo de contacto, se
desgasta con el paso de los años. Cuando el hilo de contacto se ha desgastado
aproximadamente un 20 K, debe ser cambiado. Esto ocurre aproximadamente a los 15
años.
Si en algún punto se ha desgastado el hilo de contacto un 30 %, existe el peligro de que

se rompa. El tramo desgastado debe ser cortado y reemplazado por uno nuevo.
INDICACION
Para apreciar el desgaste a tiempo del hilo de contacto, se debe
medir siempre en los mismos puntos y en espacios de tiempo
periódicos. Memorizar los resultados por escrito.
Sugerimos la medición con un micrómetro, en lo lugares cualesquiera del sistema y en

los siguientes puntos:
- Zona de arranque en las subidas
- Cruces de hilos de contacto en las agujas
- Bajo puentes
- Antes y después de aisladores de sección
Si el hilo de contacto muestra en toda su longitud un grueso uniforme y una superficie de

contacto bien pulida, es señal de que el contacto eléctrico dinámico entre el hilo de
contacto y el pantógrafo se produce sin problemas.
7.4 REPARACIÓN
7.4.1 Cambio de un trecho corto de hilo de contacto
PELIGRO
reparación
Si se renueva un segmento corto de hilo de contacto dañado, colocar en ambos

extremos grifas de unión. Las grifas de unión, fig. 10, incrementan la fricción sobre el hilo
de contacto en el punto de montaje. Si dentro de un vano de tensionamiento hay varias
grifas de unión, el hilo de contacto de este vano debe renovarse por completo.
Al hacer el cambio, no debe variarse el lugar de montaje de las péndolas, brazos de

atirantado y rueda de tensor objeto. Esto se logra cambiando el segmento dañado por
otro de igual longitud.
Sujetar un segmento del hilo de contacto de aproximadamente 160 mm de largo

Figura 10. Grifa de Unión del Hilo de Contacto

Figura 11. Cambio de un trecho corto defectuoso del Hilo de Contacto

Figura 12. Reparación de Rotura de Hilo de Contacto

Obligatoriamente se debe proceder como sigue:
a. Marcar y medir la porción del hilo a cambiar en el hilo de contacto viejo,

Fig. 11 (2).
b. Cortar un trozo de hilo de contacto de la bobina aproximadamente 40

cm más largo que el requerido. El trozo de hilo de contacto tiene la
curvatura de la bobina y por lo tanto debe ser enderezado con taco de
madera y mazo de cobre. Como los extremos no se pueden enderezar
fácilmente, se cortan de forma que el segmento de hilo de contacto
tenga la longitud exacta deseada.
c. Colocar a derecha e izquierda de las marcas, aproximadamente a 1 m

de distancia, grampas-cuña y asegurar la cuña con el mazo. Colgar un
aparejo de 1,5 t en el ojal de la grampa-cuña con la cara plana de la caja
hacia arriba (3). Poner el aparejo en tensión y asegurar nuevamente la
cuña. Accionar el aparejo hasta que el segmento del hilo de contacto
localizado entre las grampas se encuentre claramente libre de tracción
(4).
d. Cortar el hilo de contacto viejo, aproximadamente en el punto medio

entre las marcas, y enderezar los extremos (5).
Cortar los extremos del hilo de contacto en las marcas. Comprobar en
los dos cortes, si la superficie de corte es plana y perpendicular al cable.
Con esto se garantiza, que en el montaje posterior la separación en los
puntos de contacto sea lo más pequeñas posibles. Limar las superficies
de corte.
e. Unir el segmento del hilo de contacto nuevo con ayuda de dos grifas de
unión. fig. 10 y 11 (6), observar las indicaciones de montaje para la grifa
de unión.
f. Aflojar el aparejo, hasta que el nuevo hilo de contacto soporte

nuevamente la tensión. Retirar el aparejo y las grampas-cuña (7).
g. Igualar por medio de una lima la cara inferior del hilo de contacto nuevo
con la superficie de fricción del hilo de contacto viejo.
h. Comprobar la posición correcta de las péndolas y brazos de atirantado

vecinos.
Figura 13. Como enderezar el Hilo de Contacto.
7.4.2 Cambio de la totalidad del hilo de contacto en un vano
PELIGRO
reparación
a. Para esto se requiere un vehículo para inspección de la catenaria Fig.

14.
b. b) Se monta una bobina de hilo de contacto en el portabobinas en
sentido de la dirección correcta de desarrollo del cable. El largo del hilo
de contacto en la bobina debe tener, por lo menos, 25 m más que el
segmento de hilo de contacto a cambiar. Los 25 m adicionales se
requieren para que al final del tendido haya unas vueltas de cable en la
bobina. Sólo así puede tensarse el hilo de contacto, con el portabobina
frenado y aprovechando la tracción del vehículo.
ATENCION
Hay que proceder con cuidado, ya que por su elasticidad y su
tendencia a ocupar su forma original, puede saltar bruscamente
(peligro de accidente).
c. Soltar la porta bobina el extremo del hilo de contacto.

Figura 14. Vehiculo para Inspección en el Cambio de un Hilo de Contacto

d. Con ayuda de una curvadora, Figura15, se fija en el extremo del hilo de

contacto una grampa-cuña.
Figura 15. Colocación de Grampa-Cuña en extremo de Hilo de Contacto

e. Se comienza con una rueda de tensor objeto y se procede así:

1- Bloquear la rueda de tensor Fig. 16
Figura 16. Bloqueo De La Rueda De Tensor
2- Con un aparejo de 1,5 t liberar de la tensión mecánica el segundo

aislador después de la rueda de tensor, Fig. 17, y liberar la grampa-cuña
del hilo de contacto sacando el bulón de la corona del aislador, Fig. 19.
Figura 17. Cambio del Hilo de Contacto completo en un vano

3- Asegurar en la grampa-cuña el nuevo hilo de contacto con el perno

del aislador suelto.
ATENCION
No soltar el aparejo del hilo de contacto viejo, ya que este está
todavía tensado
4- El vehículo para inspección de la catenaria marcha a la velocidad de

una persona caminando, en dirección de la rueda de tensor contraria.
Así se desenrolla el hilo de contacto de la bobina. El personal en la
plataforma cuelga provisoriamente el hilo de contacto en cada péndola
con ayuda de ganchos "C", Fig. 14. Para evitar dobleces en el hilo de
contacto, el vehículo ha de marchar con velocidad constante y la bobina
ha de estar ligeramente frenado.
5- Cuando se ha tendido aproximadamente un tercio del trecho, se tensa

el nuevo hilo de contacto con la fuerza de tracción del vehículo para
inspección de la catenaria, frenando en primer lugar la portabobina y
parando a continuación el vehículo para inspección de la catenaria.
Colocar un segundo aparejo entre el hilo viejo y el nuevo y tensar este
aparejo, Fig. 18.
Figura 18. Cambio del Hilo de Contacto completo en un vano

Figura 19. Detalle de la Grampa Cuña

6- El vehículo para inspección de la catenaria recorre ahora el segundo
tercio del trecho. Colocar entonces un tercer aparejo entre el hilo viejo y
el nuevo
7- Un segundo grupo de trabajadores en otro vehiculo de inspección

realizan su trabajo entre el primer aparejo "A" y el segundo "B", controlan
la posición correcta de las estrías del hilo de contacto (torsión) y asegura
los brazos de atirantado del hilo de contacto viejo en el hilo de contacto
nuevo. Engrasar el punto de enganche.
8- Cambiar las péndolas del hilo de contacto viejo al nuevo y

asegurándolas. Engrasar los puntos de sujeción.
9- El segundo vehículo viaja en un principio únicamente hasta el aparejo

"B". Una vez llegados allí, regresan, aflojan el aparejo "A", lo desmontan,
cortan el hilo de contacto viejo en trozos y dejan estos al lado de la vía.
En el siguiente tercio del trecho, los grupos de trabajadores realizan los
mismos trabajos que han sido descritos en 7 y 8.
11- Cuando el primer vehículo para inspección de la catenaria llega

hasta la rueda de tensor opuesta, se tiene que bloquear esta rueda, Fig
16.
12- Con ayuda de otro aparejo se libera el hilo de contacto viejo de los
pernos, y se ajusta el nuevo hilo de contacto después de haberle
colocado una grampa-cuña.
13- Una vez que el segundo vehículo haya fijado por completo el nuevo
hilo de contacto, pueden liberarse nuevamente las ruedas de tensor.
INDICACION
Como en el transcurso de los meses siguientes el hilo de contacto
nuevo se estira, al cabo de aproximadamente medio año se
colocarán de nuevo las péndolas en posición vertical, se desplazarán
las uniones eléctricas y se ajustarán los brazos de atirantado y las
ruedas de tensor.
7.4.3 Reparación de una rotura en el cable mensajero
PELIGRO
reparación
Si se rompe un cable mensajero, deben revisarse los extremos a ambos lados de la rotura, buscando
posibles daños en las fibras del cable y cortando los segmentos dañados. Zunchar aproximadamente a
5 mm del punto de corte, Fig. 20 (A). El zuncho evita que el cable se deshilache. Para meter fácilmente
los extremos del cable en el elemento de unión se corta el cable con una segueta de hierro.
Figura 20. Zuncho para Cable Mensajero
Los siguientes pasos para la reparación del cable mensajero son:
a) Cortar un trozo de cable de cobre de 150 mm2 de sección de la bobina de cable de repuesto, con una
longitud mayor que la del trozo a reemplazar.
b) Preparar una punta del cable para meterla en el elemento de unión, zunchándola como arriba
descrito.
c) Meter la punta del cable preparado en el elemento de unión, hasta que el zuncho haga tope con el
elemento de unión. Fig. 20 (B).
d) Retirar el zuncho.
e) Deslizar la punta del cable hasta el centro del elemento de unión.
f) Meter por el otro lado del elemento de unión la punta del cable de repuesto.
g) Con la tenaza estranguladora, Fig. 21, prensar el elemento de unión en los puntos marcados.
Empezar en el centro.
h) Colocar grampas-cuña y unir los extremos sueltos de los cables con un aparejo de 1,5 t.
j) Cortar el trozo de cable de repuesto en la longitud precisa para completar el cable mensajero.
k) Meter las puntas de los cables en otro elemento de unión y prensarlo.
l) Desmontar el aparejo y las grampas-cuña.

Figura 21. Tenaza estranguladora
7.4.4 Reparación del cable mensajero doble, cuando se han roto simultáneamente
ambos cables mensajeros.
PELIGRO
reparación
Aquí se trabaja, en principio, tal y como se describió en la sección 6.4.3.
En lugar del aparejo de 1,5 t debe emplearse uno de 3 t. Además los pares de cable tienen que tensarse
por medio de ruedas de igualación, Fig. 22, para garantizar que la fuerza de tracción se reparte
uniformemente en ambos cables.
Figura 22. Reparación de Rupturas en Cables Mensajeros Dobles
7.4.5 Péndola provisional

La péndola provisional, Fig. 23, se puede construir y montar rápidamente, y su longitud
se modifica con facilidad. Por ello es de gran ayuda en modificaciones o fallas que
ocurran en la catenaria. La péndola provisional debe permanecer montada en la
catenaria sólo hasta que sea posible reemplazarla por una original nueva.
Observar las siguientes condiciones para el montaje:
a) Emplear alambre de cobre y no de hierro para evitar la oxidación.

b) Montar un guardacable aislador para evitar que se queme el alambre de cobre.
Las péndolas provisionales deben reemplazarse a la larga por las correctas, para facilitar
el flujo de las corrientes de igualación entre el cable mensajero y el hilo de contacto.
Figura 23. Péndola Provisional
7.4.6 Péndolas
Las péndolas se construyen como se muestra en la Fig. 24. La longitud de la péndola se
mide directamente en la catenaria, en el punto donde se encuentre una péndola
provisional, o se toman de las tablas mostradas en la sección 6.2.3.
Figura 24. Construcción de una Péndola
7.4.7 Comprobación y visto bueno

La catenaria no precisa comprobación o visto bueno después de la reparación.
Restablecer las condiciones normales de servicio.
8. BRAZOS (MENSULAS)
8.1 LUGAR DE MONTAJE:

Sobre toda la vía principal, así como en Patio y Taller
8.2 DESCRIPCIÓN Y DATOS TÉCNICOS

El brazo Fig. 25 soporta la catenaria.
En la borna torneada (6) del cable mensajero se sujetan los cables mensajeros. Por medio del
brazo de atirantado (9) se desplaza el hilo de contacto del punto medio de la vía hasta el zigzag
deseado.
Figura 25. Brazo para la Catenaria
Los elementos mensajeros del brazo son tubos de acero galvanizado al fuego, que se mantienen
unidos con ayuda de piezas articuladas de fundición maleable. La carga de estos tubos es
variable y depende de la influencia de las siguientes magnitudes:
a) Radio de la vía.
b) Lugar de montaje en el lado interno o externo de la curva.
c) Distancia entre el eje de vía y la cara externa del mástil.
La tabla de la Fig. 26 muestra como se deben modificar los diámetros de los tubos, para
garantizar la estabilidad estática según la carga.
Figura 26. Empleo de Brazos en la Catenaria
La catenaria se dilata en dirección longitudinal de la vía con cada cambio de la temperatura, ya

que se tensa automáticamente. Para facilitar el movimiento de dilatación, los brazos están
dotados de articulaciones giratorias con pasadores, Fig. 27 (1), (2), (12) y (13).
El brazo debe encontrarse en la posición perpendicular al punto fijo con una temperatura media
de operación de 40° C. Así se evita que el brazo sufra desviaciones extremas respecto a esta
posición.
Durante el montaje o comprobaciones posteriores se mide la temperatura y se monta el brazo,

de acuerdo con la Fig. 29, donde se muestra el movimiento del brazo en dependencia de la
temperatura y la distancia con respecto al punto fijo.
Figura 27. Dilatación de la Catenaria
Ejemplo:
Con 20° C y a una distancia de 600 m respecto al punto fijo, la dilatación de la catenaria respecto
a la posición normal es de 180 mm.
El brazo está doblemente aislado. Por un lado está aislado del mástil con los aisladores, Fig. 2.1-
27 (3) y (11). Por otro lado está aislado de la catenaria con la borna torneada (6) del cable
mensajero y brazo de atirantado de plástico (9).
8.3 M ANTENIMIENTO
Los brazos se deben inspeccionar cada 3 años.
PELIGRO
reparación
Una manera de detectar fallas es realizando un viaje de prueba, el cual permite tener un mejor
acceso visual al sistema.
Durante el viaje de prueba se realiza una comprobación visual de los brazos. Se deben observar
especialmente los aisladores que se encuentran en la proximidad de instalaciones industriales y
por lo tanto pueden ensuciarse fuertemente. Si además hay humedad, pueden producirse
chispas eléctricas en los aisladores. Por eso, cuando sea necesario se deben limpiar los
aisladores con trapos.
Si los aisladores han sufrido daños, por ejemplo debido a pedradas, deben ser cambiados.
Se debe comprobar el zigzag.
8.4 REPARACIÓN
8.4.1 Modificación de la longitud del cable mensajero y del hilo de contacto
El brazo ofrece muchas posibilidades de ajustar posteriormente la posición del hilo de
contacto y de los cables mensajeros. Esto puede ser necesario, cuando la posición de la
vía se varía por el paso de los trenes. La variación del peralte en este caso tiene una
influencia especial sobre el zigzag.
Si varía el peralte 1 cm, a una altura de hilo de contacto de 4,70 m, se modificó el zigzag
4,70 : 1,44, es decir en 3 cm aproximadamente.
Las posibilidades de alterar la posición en el brazo son:
a) Transversal a la vía. Correr el aislador, Fig. 25 (6), del cable mensajero sobre el
extremo libre del tubo superior (4).
b) Modificando de la altura del cable mensajero. Soltar la abrazadera de ojal (5), y

subir o bajar el tubo superior (4)
c) Modificando el zigzag del hilo de contacto. Desplazar la posición del gancho

articulado (8) en el brazo de atirantado (9), sobre el tubo inferior (lo).
d) La altura del hilo de contacto se determinó antes y después del brazo, a la altura
de las péndolas y por lo tanto sólo puede ser modificada allí. Si el zigzag es en
dirección contraria al mástil se tiene que subir el hilo de contacto
aproximadamente un 2 K. Si el zigzag es en dirección al mástil se tiene que bajar
el hilo de contacto aproximadamente un 2 K. Esto se obtiene desplazando la
abrazadera de ojal (5) sobre el tubo superior (4), o desplazando la abrazadera de
gancho (7) sobre el tubo inferior (lo).
e) Sobre las grampas actúan fuerzas elevadas, ocasionadas por la tracción de las
curvas y por el peso de la catenaria. Si se sueltan los tornillos de las grampas, se
liberan estas fuerzas siendo imposible sostenerlas con la fuerza de los músculos.
Por ello, antes de soltar los tornillos deben tomarse las siguientes medidas, para
reducir las fuerzas:
Si los cables mensajeros deben ser levantados o bajados, debe colocarse el

vehículo de plataforma bajo el brazo. Se colocó un puntal de madera gruesa, Fig.
28, de aproximadamente 1,50 m de alto bajo los dos cables mensajeros,
aproximadamente a 1 m de distancia de los brazos, sobre la plataforma elevable
y se sube esta lentamente hasta que se levante el cable mensajero y el brazo
quede libre de toda carga.
Figura 28. Apuntalamiento del Cable Sustentador
f) Si los cables mensajeros se desplazan hacia un lado de la vía, asegurarlos

lateralmente en contra de la tracción existente como se muestra en Fig. 29.
Figura 29. Fijación de los Cables Mensajeros

En dirección contraria al mástil, el aparejo se engancha en la barandal a de la

plataforma.
g) g) El hilo de contacto sólo tiene que fijarse lateralmente en curvas fuertes. En

dirección al mástil se procede de la misma manera que con los cables
mensajeros.
8.4.2 Cambio de aisladores
PELIGRO
reparación
Si se desean cambiar los aisladores, se debe liberar el brazo de la tracción lateral y

vertical de la forma descrita en 7.4.1. f).
8.4.3 Comprobación y visto bueno

Los brazos no precisan comprobación o visto bueno tras la reparación.
Restablecer las condiciones de servicio.
ANEXO A: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE LOS SECCIONADORES

s
Electromechanical operated mechanism Sicat 8WL6243/6244

GRP casing, linear stroke 200 mm
Operating Instructions Version 1.0.0
Siemens AG
Industry Sector
Mobility Division
Complete Transportation
Copyright © Siemens AG 2011. All rights reserved.

The Industry Sector, Mobility Division (I MO) of Siemens AG has introduced
and applies to
project configuration, sales, development, procurement, manufacture,
assembly, commissioning and servicing of products, systems and services of
the Rail Automation Rolling Stock and Complete Transportationand Business
Units
an integrated quality, safety, health and environmental management system in
conformity with the standards:
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
Certification was issued by DNV Zertifizierung und Umweltgutachter GmbH and

confirmed by regular audits.
If you require further copies of these Operating Instructions, please order them
through your responsible Siemens representative by quoting the title and the
document number:
A6Z00032010184
Siemens AG
Industry Sector
Mobility Division
Mozartstrasse 33b
91052 Erlangen
Germany
E-mail: techcom.el.mobility@siemens.com
Subject to change without notice!
© Siemens AG 2011
NOTE
The reproduction, transmission or use of this document or its contents is not permitted without
express written authority. Offenders will be held liable for damages. All rights, including rights
created by patent grant or registration of a utility model or design, are reserved.
Sicat® is a registered trademark of Siemens. The other names appearing in this documentation
may be trade names, the use of which by third parties for their own purposes may infringe the
rights of the respective owners.
2 / 58 Sicat 8WL6243/8WL6244 / Operating Instructions / Version 1.0.0 / A6Z00032010184

Contents
1 General ............................................ 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Sources of danger .................................... 9
3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.1 Operated mechanism 8WL6243 . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.2 Operated mechanism 8WL6244 . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 Casing with casing support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Mechanical actuating unit with motor . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Electric control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 crank handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Mechanical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Electrical part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Circuit for 230 V AC variant (4-wire technology) . . . . . . . . . . . . . . 20
5.3.2 Circuit for 230 V AC variant (3-wire technology) . . . . . . . . . . . . . . 22
5.3.3 Circuit for 24/60 V DC variant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3.4 Switch position signal on the disconnector . . . . . . . . . . . . . . . . . . 25
6 Transport and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1 Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Sicat 8WL6243/8WL6244 / Operating Instructions / Version 1.0.0 / A6Z00032010184 3 / 58

6.3 Checks on receipt .................................... 26
6.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Installation ......................................... 28
7.1 Regulations and conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Aids and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3.1 Mounting the casing on a pole . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3.2 Establish the connection to the operating linkage. . . . . . . . . . . . . 33
7.4 Connecting the electric control unit . . . . . . . . . . . . . . . . . . . . . . . 34
7.5 Assignment diagram for terminals . . . . . . . . . . . . . . . . . . . . . . . . 36
7.5.1 Terminal assignment diagram for 230 V AC operated mechanisms
(4-wire technology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.5.2 Terminal assignment diagram for 230 V AC operated mechanisms
(3-wire technology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.5.3 Terminal assignment diagram for 24 V DC and 60 V DC operated
mechnisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.6 Cable adapter (optional) for 3-wire and 4-wire technology . . . . . . 38
7.7 Connecting the floating contacts . . . . . . . . . . . . . . . . . . . . . . . . . 38
8 Commissioning ..................................... 39
8.1 Disconnector and operating linkage . . . . . . . . . . . . . . . . . . . . . . . 39
8.2 Operated mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2.1 Test of manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2.2 Testing the electromechanical function .................... 41
9 Operation .......................................... 42
9.1 Remote-controlled electrical operation . . . . . . . . . . . . . . . . . . . . . 42
9.2 Electrical local control ................................. 42
9.3 Local manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.4 Safeguarding the operated mechanism against
electrical switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10.2.1 Replacing the ventilation pipes .......................... 46

10.3 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.1 Removing the operated mechanism from a pole or structure . . . . 48
11.2 Recycling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
11.3 Dismantling the operated mechanism . . . . . . . . . . . . . . . . . . . . . . 49
12 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.1 Order No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.2 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
12.3 Mechanical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.4 Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
12.4.1 General electrical data/characteristic motor data . . . . . . . . . . . . . 52
12.4.2 Commands and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
12.5 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12.6 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12.7 Adhesive label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
12.7.1 Operated mechanism 8WL6243-0 (230 V AC) /
8WL6244-0 (230 V AC) (4-wire technology) . . . . . . . . . . . . . . . . . 55
12.7.2 Operated mechanism 8WL6243-7 (230 V AC) (3-wire technology) 56
12.7.3 Operated mechanism 8WL6243-6 / 8WL6244-6 (24 V DC) /
8WL6243-4 / 8WL6244-4 (60 V DC) . . . . . . . . . . . . . . . . . . . . . . . 57

General
1 General
These operating instructions apply to the standard version of the
Sicat® 8WL6243/6244 product, starting with model year 2010.
The Operating Instructions (according to IEC 62079:2001) are intended to make
any personnel familiar with the product.
WARNING
Failure to observe these Operating Instructions can result in serious physical injury or death.
Observe the safety warnings in Section 2 "Safety" on page 7.
Observe the warning notices in these Operating Instructions and on the product. Read these
Operating Instructions completely before installing this product. Keep these Operating Instructions
ready to hand so that you can refer to important information at all times.
Correct and safe operation of the product can be guaranteed only after proper transport, storage,
erection, installation, commissioning and careful maintenance.
NOTE
For easier understanding, these Operating Instructions do not contain comprehensive information
about all product types and cannot cover every conceivable installation, operation and mainte-
nance condition.
If you require further information, or if specific problems arise that are not dealt with sufficiently in
these Operating Instructions, please contact your local Siemens representative.
The contents of these Operating Instructions do not form part of or have no effect on any earlier
or existing contract, agreement, or legal relationship.
All obligations on behalf of Siemens are based upon the respective purchase contract, which also
contains the complete and exclusively applicable warranty conditions. The contractual warranty
conditions are neither extended nor limited by the contents of these Operating Instructions.

Safety
2 Safety
2.1 Description of the warning notices

These Operating Instructions contain warnings based on signal words to
indicate the degrees of danger.
Such warning notices can also be affixed on the product in the form of signs,
stamps or adhesive labels.
Symbol SIGNAL WORD

Meaning
Symbol Signal word Meaning
Danger in the context of these Operating Instructions and the warning

notices on the products themselves, means that death or serious
physical injury will occur if the corresponding safety measures in
these Operating Instructions are not obeyed.
Warning in the context of these Operating Instructions and the warning

physical injury can occur if the corresponding safety measures in
these Operating Instructions are not obeyed.
Attention in the context of these Operating Instructions and the warning

notices on the products themselves, means that slight physical
injury or damage to property can occur if the corresponding safety
measures in these Operating Instructions are not obeyed.
Attention in the context of these Operating Instructions and the warning

notices on the products themselves, means that damage to
property can occur if the corresponding safety measures in these
Operating Instructions are not obeyed.
Note in the context of these Operating Instructions is important informa-

tion related to the product or to the respective section of the docu-
mentation to which special attention is to be drawn.

Safety
2.2 Intended use
WARNING
Use of the product for purposes that are not intended can cause death, serious physical injury,
considerable damage to property and environmental pollution.
Use the product only for its intended purpose (see also section 3 "Purpose and
use" on page 10).
Use complies with the intended purpose if:
• the product is operated in accordance with the agreed terms of delivery and
the stated technical specification, and
• any supplied devices and special tools are used exclusively for the intended
purpose and in accordance with the appropriate instructions in these Oper-
ating Instructions.
All other methods of use are forbidden unless explicit written agreement has
been issued by Siemens AG.
2.3 Personnel qualification

A person is qualified if he/she is familiarized with:
• the installation,
• the construction,
• the operation,
• the maintenance of the product and
• the associated dangers.
Moreover, all persons performing installation, commissioning, operation and
maintenance of the product must also possess qualifications and experience in
the following basic skills:
• installation methods,
• working in accordance with, and on the basis of drawings,
• working in accordance with the operating instructions,
• accident prevention and safety regulations,
• commissioning methods and procedures,
• first aid.
Please refer to national requirements (e.g. BGV A 3 in Germany, EN 50110 in
Europe).
2.4 Safety requirements

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

Safety
Instruct personnel regularly on the currently applicable rules and regulations, the
generally applicable accident prevention regulations and legally binding safety
instructions.
Irrespective of these, the following five safety rules apply in compliance with
EN 50110-1:2004:
NOTE
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 adjacent live parts
Use personal protective equipment as specified by national accident prevention

regulations (e.g. in Germany BGV A 1 or BGR 189-199).
2.5 Sources of danger

If the requirements and conditions in the Operating Instructions have not been
obeyed or the safety instructions have not been followed, then the following
dangers are posed:
DANGER
Risk of fatal injury through high voltage at the electrical systems.
Observe the warning notices in these Operating Instructions and on the product.
DANGER
Risk of fatal injury through railway vehicles during work in track area.
Observe the regional applicable regulations and the instructions of the plant manufacturer and
operator.
DANGER
Risk of fatal injury through work in heights on working platforms, ladders and poles.
operator.
ATTENTION
Risk of injury due to falling and/or toppling parts and risk of being trapped by moving parts.
Observe the warning notices in these Operating Instructions and on the product.

Purpose and use
3 Purpose and use

The electromechanical operated mechanism Sicat 8WL6243/6244 is part of a
contact line system and is used for the remote operation of disconnectors on
overhead contact line poles or on structures (see Figure "Schematic arrange-
ment of disconnector, operating linkage and operated mechanism on pole." on
page 10).
The electromechanical operated mechanism is generally controlled remotely.
Provided all safety rules are observed, it can also be switched via the integrated
electric control unit with local controls directly on the unit. For testing or mainte-
nance purposes, or in case of a power failure, the electromechanical operated
mechanism can be operated manually.
The mechanical connection between the electromechanical operated mecha-
nism and the disconnector is to be established preferably with an operating
linkage made of GRP.
NOTE
The GRP operating linkage and the disconnector are not part of the scope of supply. Use of the
GRP operating linkage is necessary for galvanic separation of the operated mechanism to ground.
The electromechanical operated mechanism has a linear stroke of 200 mm.

A maintenance-free mechanical system generates the setting force of at least
4.0 kN in the disconnector's direct closing or opening phase.
disconnector
operating linkage
operated mechanism
Schematic arrangement of disconnector, operating linkage and operated mechanism on

pole.

Design
4 Design
4.1 General
The electromechanical operated mechanism consists of the following modules
(see Figure "Assemblies of the operated mechanism" on page 11):
EIN/ON
AUS/OFF
4
1
1 casing
2 casing support
3 actuating unit with motor
4 electric control unit with local controls
5 crank handle
Assemblies of the operated mechanism

Design
4.2 Variants
NOTE
If electrical control models or colors other than the ones named in these operating instructions are
used, please contact your local Siemens representative.
The operated mechanism is available in two GRP casing versions of differing

lengths.
4.2.1 Operated mechanism 8WL6243
Operated mechanism in a short GRP casing

Supply voltage Order No. Description
230 V AC 8WL6243-0 4-wire technology, color RAL6009
230 V AC 8WL6243-7 3-wire technology (without local control),
color RAL6009
60 V DC 8WL6243-4 color RAL6009
4.2.2 Operated mechanism 8WL6244
Operated mechanism in a long GRP casing

Supply voltage Order No. Description
230 V AC 8WL6244-0 4-wire technology, color RAL6009
230 V AC 8WL6244-0G 4-wire technology, color RAL9007
The long casing offers space for additional options (e.g. for installing a DC/DC
transformer).
4.3 Casing with casing support

The essential components are shown in Figures "Casing with support plate
(8WL6243)" on page 13 and "Parts on the casing" on page 13.
The casing (1) of the electromechanical operated mechanism is made of fiber-
glass reinforced plastic (GRP). The closed casing meets the requirements of
IP54 degree of protection in compliance with IEC 60529. To this end, the
following measures have been realized:
• A rubber seal is fitted all around the edge of the casing in order to prevent
the ingress of dust or splashwater.
• The bushing for the control rod in the upper part of the casing is sealed by
means of a bellows (1b). This additionally protects the control rod and the
casing's bushing against soiling.

Design
• The polyamide cable glands (1c) and (1d) (see Figure "Parts on the casing"
on page 13) in the bottom side of the casing have an integrated sealing lip.
• The interior of the casing is ventilated by means of a ventilation pipe (1e)
provided in the bottom of the casing.
1a
operated mechanism 8WL6243
1b
2
2f
2e 2a
2d 2c
2b
1 casing 2b lock washer

1a swivel lever lock 2c cap and hexagon nut
1b bellows 2d insulating bush
2 casing support 2e Neoprene seal
2a M10 threaded bolt 2f countersunk head screw, M10x16
Casing with support plate (8WL6243)
8WL6243 8WL6244
1c
1e 1e
1c
1d 1d 1d
1c cable gland M16 (optional) 1e ventilation pipe

1d cable gland M25
Parts on the casing
If condensate should form inside the casing as a result of air entering and
leaving the unit in dependence on temperature fluctuations, it can flow off
through the ventilation pipe (1e). A filter in the ventilation pipe prevents the
ingress of airborne dirt particles.

Design
The left-hinged casing door of the operated mechanism is locked by a mechan-

ical swivel lever lock (1a). In order to prevent unauthorized opening, the
operator can install a semi-profile lock barrel in the door handle of the swivel
lever lock. The opening angle of the casing door is approximately 180° and
depends on the selected method of installation.
The assignment diagram for the terminals, notes on operation and the rating
plate are located on the inside of the casing's door.
A casing support (2) is provided to enable the electromechanical operated
mechanism to be mounted on an overhead contact line pole or on a structure.
Section 7 "Installation" on page 28 describes how the casing support is fastened
to the pole or structure. Neoprene rubber seals fitted onto the four continuous
M10 threaded bolts (see Figure "Fastening on the pole (example 8WL6243)" on
page 32) provide a seal between the rear of the casing and the casing support.
Forces applied to the actuating unit are transmitted into the pole via these
threaded bolts.
Insulating sockets (2d) on the four M10 threaded bolts (2a) are used for galvanic
separation of the pole or structure and the PE conductor of the operated mech-
anism.
4.4 Mechanical actuating unit with motor

The essential components of the mechanical actuating unit are shown in Figures
"Components of the mechanical actuating unit" on page 15 and "Geneva
gearing" on page 15.
The mechanical actuating unit is fitted on a mounting plate (3e) that is fastened
to the rear wall of the casing with two screws.
The operated mechanism is joined to the operating linkage on the connecting
clevis (3g) of the control rod (3f).

Design
3i
3h
3a
3b
3c
4a
4b
3g 3f 3e 3d
3a motor 3g connecting clevis

3b planetary gearing 3h square drive for crank handle
3c claw coupling 3i cam
3d worm gearing 4a upper limit switch
3e baseplate 4b lower limit switch
3f control rod
Components of the mechanical actuating unit
3n 3p
3r
3m 3m 3k
3k setting slide 3p operating lever

3m guide rod 3r operating pin
3n Main axle
Geneva gearing

Design
4.5 Electric control

Components of the electric control:
• electric control unit with local controls
• two limit switches
• door contact switch
• cabling
Electric control unit with local controls
The essential components of the electgric control unit are shown in Figure
"Electric control unit" on page 16.
4n 4c 4r 4s 4u 4v 4w
4m EIN/ON
AUS/OFF
4d
4e
4k 4i 4h 4g 4f
4c mode selector switch, lockable 4m pushbutton switch, red, EIN/ON

4d casing 4n top fastening bracket
4e terminal block X4 door switch signal 4r terminal block X9 (optional)
4f terminal block X3 ON/OFF signal 4s terminal block X8 for strain gauge
4g terminal block X2 ON/OFF command 4u terminal block X7 OFF limit switch
4h terminal block X1 motor 4v terminal block X6 ON limit switch
4i pushbutton switch, green, AUS/OFF 4w terminal block X5 door switch
4k bottom fastening bracket
Electric control unit
The electric control unit is arranged in the upper part of the operated mecha-
nism. The casing (4d) with its two fastening brackets (4k) and (4n) is bolted to
the baseplate (3e) and the mounting block of the worm geaing (3d).
The lockable mode selector switch (4c) and the two pushbutton switches (4i)
and (4m) for electrical operation of the operated mechanism locally are located
on the front of the casing (4d).
The electric control unit with local controls (permanent power supply) contains
the evaluator of the position indication with rotary encoder unit on the Sicat DMS
disconnector.

Design
The various terminal blocks are located at the sides. The terminals are suitable
for connecting wires with a maximum cross-section of 4 mm² or 1.5 mm².
The assignment diagram for terminals is fitted on the inside of the casing door.
The internal cabling establishes the electrical connection between the control
unit with local controls and the motor of the actuating unit, the limit switches and
the door contact switch in the casing of the operated mechanism.
Electric control unit without local controls
Operated mechanisms without a permanent power supply (e.g. 3-wire tech-
nology 230 V AC) do not have any pushbutton switches (4i) and (4m) on the
front of the casing (4d). The terminal block configuration is therefore different
(see Section 7.5 "Assignment diagram for terminals" on Page 33).
Supply cable
The electrical supply cable consists of a multiple-core cable and is routed into
the operated mechanism's casing through an M25 cable gland (1d). The cable
diameter must not exceed 13 mm.
Integrated evaluator of the Sicat DMS disconnector position indication
The evaluator for the Sicat DMS disconnector position indication is integrated in
the electric control unit with permanent power supply.
The M16 cable gland (1c) (see Figure "Parts on the casing" on page 13) is
optionally intended for the cable of the rotary encoder unit for Sicat DMS. You
can refer to the relevant installation instructions for notes on use and installation
of Sicat DMS. Order these through your local Siemens representative by quoting
the document number A6Z00010806114.
Floating contact
The electromechanical operated mechanisms with permanent power supply are
equipped with one floating additional contact for each end position (one normally
open (NO)) (see Section 5.3 "Electrical part" on page 20 for a description of its
realization).
4.6 Crank handle

In the idle position, the crank handle for local manual operation is stored in the
spring mount on the Geneva gearing (see Figure "Assemblies of the operated
mechanism" on page 11).

Function
5 Function
5.1 General
The operated mechanism is connected to the disconnector by an operating
linkage. The necessary stroke of 200 mm is generated by the electromechanical
actuating unit (3) of the operated mechanism.
A brief pulse for control of the motor current is generated by the remote control
or by operating the pushbuttons (4i) or (4m) directly on the electric control unit
with local control (4) (see Figure "Electric control unit" on page 16). Starting
from the motor, linear movement of the control rod (3f) and thus the setting
stroke are realized via the planetary gearing (3b), the Geneva gearing (3p) and
the worm gearing (3d). If the control rod moves upwards, the disconnector is
closed, i.e. the contact blades of the disconnector are inserted into the contact
springs (see Figure "Example set of contact of the closed 3 kV DC disconnector
8WL6134" on page 39).
The motor current is switched off when the control rod reaches the end position
at the upper limit switch (4a), which is forcibly switched by a cam (3i) of the
Geneva gearing.
In order to open the disconnector, the control rod must be moved in the opposite
direction. The required control pulse is converted by the electric control unit and
the motor is activated. As a result of the motor being operated in the opposite
direction of rotation, the setting movement in the system is reversed. The control
rod moves down and the disconnector is opened. The motor current is switched
off when the end position at the lower limit switch (4b) is reached.
The following table shows the position of the control rod, the switch position of
the disconnector and the visual indication in the operated mechanism.
Control rod Disconnector LED in the
pushbutton
Retracted into casing Open Lit green
Extended out of casing Closed Lit red
When the switch position indication with rotary encoder unit is integrated into the
disconnector, the feedback signals are passed on to SCADA (only in the case
of operated mechanisms with a permanent power supply). You can find further
information in the appropriate Sicat DMS documentation. Order this through
your local Siemens representative by quoting the document number
A6Z00010806114.

Function
5.2 Mechanical features

The motor (3a) drives the actuating unit. The planetary gearing (3b) and the
worm gearing (3d) reduce the motor speed to an optimum extent. The Geneva
gearing (see Figure "Geneva gearing" on page 15) converts the rotary motion
to a linear setting motion.
3p 3k
3i
3t
3h
3a
3f 3b
4a
4b
3d
3a motor 3k setting slide

3b planetary gearing 3p operating lever
3d worm gearing 3t fitting panel
3f control rod 4a upper limit switch
3h square drive for crank handle 4b lower limit switch
3i cam
Actuating unit with motor
Due to the geometry of the Geneva gearing (operating lever (3p) and setting
slide (3k)), the control rod is locked mechanically in both end positions.
According to the force/distance characteristic of the Geneva gearing, the setting
force reaches its highest value of at least 4 kN in the range of the end position
(entry and exit of the contact blades on the disconnector's contact set). After half
the setting distance, the setting force is at least 2.5 kN (involving movement of
the operating linkage and of the disconnector).
The position and geometry of the Geneva gearing are coordinated so that direct
starting of the motor takes place in the end positions without any external load
influence.
Braking of the motor's rotary motion to protect against blocking when the end
positions are reached takes place electrically.
Operation with crank handle
The control rod (3f) is moved manually by turning the crank handle (5) fitted on
the square drive (3h) (square, 8mm). Two bevel gears in the worm gearing (3d)
convert the rotary motion to a linear motion. Depending on the direction of
rotation with the crank handle, the control rod is moved up or down and the
disconnector is either opened or closed.
Optionally, when using a square adapter the control rod can be moved by means
of a cordless screwdriver.

Function
5.3 Electrical part

ATTENTION
Before selecting operated mechanisms, users must clarify the interface for integration of the
control system and activation of the operate mechanism's electric control unit.
If electrical control models other than the ones named in these operating instructions are used,
please contact your local
Siemens representative with regard to the possibility of using them.
5.3.1 Circuit for 230 V AC variant (4-wire technology) Command Off (L1), Message On
Command On (L1), Message Off
Message door contact

Floating output
Floating output
Floating output
Message On
Message Off
PE
L1
N
-Q1
Motor operated mechnism -X_PE
230 V AC
-D1 -X1 1 2
-X2 1 2 3 4
-X4 1 2 3 4 5 6
Control
-X8 1 2 3
-X7 1 2 3 4
-X6 1 2 3 4
-X5 1 2 3 4
BR WH BU
-W7 -W6 -W5
1 2 3 4 1 2 3 4 1 2 3 4
-S7 -S6 -S5
Rotation angle sensor
for Sicat DMS
-M1 on the disconnector
Position Off Position On Door contact
-B1
M
OFF ON
Motor
optional for Disconnector Monitoring System (Sicat DMS)
Schematic diagram for 230 V AC (4-wire technology)
The operated mechanism was conceived for a supply voltage of 230 V AC for
operation and control (commands and signals). The required permanent supply
voltage is provided over two conductors (L1 and N). Commands are entered and
signals are issued (ON command/feedback signal, OFF command/feedback
signal) via combined control and feedback signal lines (4-wire technology).
Within the control, 12 s run time monitoring is implemented as an electrical safe-
guard against overload.

Function
Mechanical limit switches are used for switching off the motor when the end
position is reached. The control's own rated current requirements in the
operated mechanism's idle state is specified in Section 12.4 "Electrical data" on
page 52. The indicated value does not include the operator-dependent power
requirement resulting from external use of the potentials from the ON/OFF
signals.
When the default electronic feedback signal is used (4-wire technology), the
"DOOR CONTACT" signal is linked to the ON and OFF signals.
Electrical remote control
Preconditions for electrical remote control are that the mode selector switch (4c)
is in the "1" position and that the casing door is closed. When the casing door is
open, the commands are inactive and feedback signals are deactivated. As a
result, electrical remote control is no longer possible.
By default, the feedback signals when using 4-wire technology are evaluated by
an external actuating unit. To this end, a pulsating direct current is coupled into
the control lines. The position signal is not evaluated during electrical actuation
of the operated mechanism. With an electronic feedback signal, the position
signal when using the floating signaling contacts can be permanently deter-
mined and transmitted.
If the door is opened during an operating process, the operating process
continues until the end position is reached.
Electrical local control
Electrical local control performed directly at the operated mechanism is only
possible when the door of the casing is open (electronic end position feedback
signal deactivated). As a result, remote control of the operated mechanism is
interrupted.
When a pushbutton (4i) or (4m) is pressed, the control rod (3f) of the actuating
unit moves in the selected direction. When the end position is reached, the
corresponding limit switch (4a) or (4b) is operated, the motor current is inter-
rupted and the control rod comes to a standstill. When the end position is
reached, the LED in the corresponding pushbutton lights up (see Section 5.1
"General" on page 18 and Section 9.2 "Electrical local control" on page 42).
When the mode selector switch is in the "0" position, operation is only possible
with the crank handle.
Floating contacts
Via the floating signaling contacts (NO), which are available by default, a
separate feedback signal for each end position (e.g. with 230 V AC) can be
realized if the necessary number of wires in the supply cable is increased.
Analogously to the end position signals, the "DOOR CONTACT" signal can also
be registered via a floating signaling contact. As an alternative, the floating
contacts can be used for additional signaling functions for each end position, for
example.

Function
5.3.2 Circuit for 230 V AC variant (3-wire technology)
Command On (L1), Message Off

Command Off (L1), Message On
-Q1 N
Motor operated mechnism 230 V AC
NC... Not Connected

NC
-D1 -X1 1 2
-X2 1 2 3 4
Control
-X7 1 2 3 4
-X6 1 2 3 4
-W7 -W6
1 2 3 4 1 2 3 4
-S7 -S6
-M1
Position Off Position On
OFF ON
Motor
Schematic diagram for 230 V AC (3-wire technology)
The operated mechanism was conceived for a supply voltage of 230 V AC for
operation and control (commands and signals). Contrary to the version with 4-
wire technology, the mechanism with 3-wire technology is only supplied with
energy during the electrical operating process (temporary energy supply).
Therefore, there is no electrical local control.
Via combined energy, control and feedback signal lines (ON command/
feedback signal, OFF command/feedback signal), the operated mechanism is
powered during electrical actuation, commands are entered and signals are
issued (3-wire technology)
position is reached. A door contact switch is not implemented by default.
is in the "1" position. As there is no door monitoring, opening the door does not
influence remote control.

Function
By default, the feedback signals when using 3-wire technology are evaluated by
an external actuating unit. To this end, a pulsating direct current is coupled into
the control lines. Note that evaluation of the position signal is not possible during
electrical actuation of the operated mechanism.
Due to the temporary power supply, the operated mechanism does not feature
local electrical operation directly on the operated mechanism.
When the mode selector switch is set to "0", remote control becomes inactive
and thus the operating process can be realized reliably with the crank handle.
Floating contacts
The version with 3-wire technology has not additional floating signaling contacts.
5.3.3 Circuit for 24/60 V DC variant
Message door contact (U+)

Command Off (U+)
Command On (U+)
Power supply (U+)
Power supply (U-)
Message On (U+)
Message Off (U+)
Floating output
Floating output
Message On
Motor operated mechnism 24/60 V DC Message Off
NC... Not Connected
NC
NC
NC
NC
NC
1 2 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6
-D1 -X1 -X2 -X3 -X4
Control
-X8 1 2 3 -X7 1 2 3 4 -X6 1 2 3 4 -X5 1 2 3 4
BR WH BU
-W7 -W6 -W5
1 2 3 4 1 2 3 4 1 2 3 4
-S7 -S6 -S5
Rotation angle sensor
for Sicat DMS
-M1 on the disconnector
Position Off Position On Door contact
-B1
M
OFF ON
Motor
optional for Disconnector Monitoring System (Sicat DMS)
Schematic diagram for 24/60 V DC
The operated mechanism was conceived for a supply voltage of 24/60 V DC for
operation and control (commands and signals). The required supply voltage is
provided via two conductors (+24/+60 V DC and 0 V DC).

Function
Commands are input and signals are output via control cables (ON command,
OFF command, ON signal, OFF signal, door contact switch). The circuits for
commands and signals are not electrically isolated from the motor circuit.
position is reached. The control's own rated current requirements in the
operated mechanism's idle state is specified in Section 12.4 "Electrical data" on
page 52. The indicated value does not include the operator-dependent power
requirement resulting from external use of the potentials from the ON or OFF
and door signals.
is in the "1" position and that the casing door is closed. A signal is sent to the
telecontrol system when the casing door is open.
The setting commands are sent to the operated mechanism by means of a +24/
+60 V DC potential through separate command lines. The signals for the ON or
OFF switch positions and for the door signal are routed through
+24/+60 V DC potentials of the supply voltage through separate signal lines to
the telecontrol system or the central control system. If the door is opened during
setting, the operating process ends when the end position is reached.
Electrical local control performed directly at the operated mechanism is only
possible when the door of the casing is open. When the door is open, the door
contact switch dispatches the signal to the remote control system.
ATTENTION
Operators must ensure external suppression of the ON or OFF setting commands by the remote
control when the door of the operated mechanism door is open. Only in this way can remote
control of the operated mechanism be suppressed. The door signal can be used for this purpose.
When a pushbutton (4i) or (4m) is pressed, the control rod (3f) of the actuating
unit moves in the selected direction. When the end position is reached, the
corresponding limit switch (4a) or (4b) is operated, the motor current is inter-
rupted and the control rod comes to a standstill. When the end position is
reached, the LED in the corresponding pushbutton lights up (see Section 5.1
"General" on page 18 and Section 9 "Operation" on page 42).

Function
ATTENTION
Turn the mode selector switch to "0" only in an emergency during an operating process. This
immediately interrupts the operating process. The switching status of the disconnector is not clear.
The contact line may carry voltage.
When the mode selector switch is in the "0" position, operation is only possible
with the crank handle.
Floating contacts
Via the floating signaling contacts (NO), which are available by default, a
separate feedback signal for each end position (e.g. with 230 V AC) can be
realized if the necessary number of wires in the supply cable is increased.
5.3.4 Switch position indication on the disconnector
Integration of the Sicat DMS disconnector position indication with rotary encoder
unit into the control of the operated mechanisms with a permanently power
supply is possible as an option. The electric control contains an integrated eva-
luation unit for the switch position indication. The evaluator processes the
signals of the rotary encoder unit of the disconnector and of the limit switches in
the operated mechanism. The evaluated signals are forwarded to SCADA.
You can refer to the appropriate documentation for further information on the
Sicat DMS switch position indication. Order this through your local Siemens
representative by quoting the document number A6Z00010806114.

Transport and Storage
6 Transport and Storage
6.1 Transport conditions

The means of transport to and at the installation site must be suitably designed
and have the load-bearing capacity needed to transport the disconnectors.
When lifting the device, please bear in mind the weight (see Section 12.2
"General data" on page 51) and the center of gravity of the operated mecha-
nism.
NOTE
The operated mechanism must be protected against shock and damage. Take special care to
ensure that the paintwork of the casing remains undamaged and that the linkage with bellow as
well as the cable gland and ventilation pipes are not damaged.
Transport the operated mechanism lying on its rear panel. During transport, the
linkage must be in the retracted position in the casing.
6.2 Packaging
For batches of up to five operated mechanisms, one layer of the mechanisms is
to be placed on a suitable pallet for transport. Operated mechanisms must not
protrude beyond the pallet. The operated mechanisms are to be individually
wrapped in 10 mm bubble wrap. Adequate precautions, for example edge
protection and coverings, must be taken during transport to ensure protection
against anything acting on the items from above and from the sides. Do not
stack several pallets one on top of the other.
For batches of more than five operated mechanisms, each batch is to be trans-
ported in a lying position in a wooden crate. For this kind of transport, each
operated mechanism must be wrapped in suitable protective envelope.
A packet of dessicant (silica gel) is inside the operated mechansim. Necessary
notes on transport and storage must be placed on the packaging.
6.3 Checks on receipt

NOTE
If the consignment is damaged, the scope and cause of the damage are to be established and
documented in writing and reported to the supplier without delay. The forwarding agent is to be
enlisted to record the facts if transport damage has occurred. A written record is essential for
damage claims.
The shipment must be checked immediately on receipt for damage and for
completeness based on the delivery notes.
Scope of supply:
• Operated mechanism
• crank handle (in the operated mechanism)

Transport and Storage
• Casing support (2) with 4 threaded bolts (2a), lock washers (2b), insulating
bushes (2d), seals (2e) and hexagon nuts with caps (2c) each.
• Six or four hexagon socket countersunk screws M10x16 (2f) for fitting the
casing support (in the operated mechanism)
6.4 Storage
Bear in mind the weight of the operated mechanism and the permissible load-
bearing capacity of the storage location. If the operated mechanisms are to be
stacked, use padded spacing timbers. Stack operated mechanisms on two
levels only and with suitable protection against pressure and damage. Until they
are installed, keep the operated mechanisms stored in a dry place and protected
against the elements.

Installation
7 Installation
These operating instructions describe how an electromechanical operated
mechanism is mounted on a pole. The procedure for mounting the operated
mechanism on a structure is analogous.
7.1 Regulations and conditions

WARNING
In order for the electromechanical operated mechanism to be operated safely, it must be mounted
and commissioned properly by qualified personnel in accordance with the warnings in these oper-
ating instructions. Failure to comply can result in death, serious injury or considerable damage to
property.
NOTE
The electromechanical operated mechanism can only be used for disconnectors with a stroke of
200 mm.
The Sicat 8WL6243/6244 electromechanical operated mechanism is supplied

ready for mounting and electrical connection. The casing support (2) (see Figure
"Casing with support plate (8WL6243)" on page 13) for fastening an operated
mechanism on a pole or a structure is included in the scope of delivery.
Mount the electromechanical operated mechanism on a side of the pole facing
away from the track. The preferred position is 90° in relation to the track (see
Figure "Mounting the operated mechanism on a pole" on page 28).
preference variants
Mounting the operated mechanism on a pole
NOTE
Use the operating linkage made of GRP for connecting the disconnector and the operated mech-
anism.
GRP operating linkage is not included in the scope of supply of the operated mechanism.
Determine the length of the operating linkage and the number of individual rods
needed in relation to the installed height of the disconnector. The necessary
clearance between the hinged pieces and the linkage guides on the pole must
be sufficient for the two switching positions of the disconnector.

Installation
The electromechanical operated mechanism is primarily designed to be

controlled and operated from a control center with the aid of a remote control
system. The distance between the telecontrol terminal device and the operated
mechanism depends on the dimensioning of the control cable (see table).
Operated mechanism Rated voltage Control cable Description
8WL6243-0 (4-wire technology) 230 V AC 5-wire 1 PE
8WL6244-0 (4-wire technology)
8WL6244-0G (4-wire technology)
8WL6243-7 (3-wire technology) 230 V AC 3- resp. 4-wire* 1 PE*
8WL6243-4 60 V DC 7-wire
8WL6244-4
8WL6243-6 24 V DC 7-wire
8WL6244-6
* project-specific
The following table contains guidelines for the cables and the resulting possible
distance from the remote control unit to the operated mechanism.
. Wire cross Maximum length of the control cable at 0.9-fold rated voltage UN
section and rated voltage UN
24 V DC 60 V DC 230 V AC
0.9-fold UN 0.9-fold UN 0.9-fold UN
UN UN UN
1.5 mm² 5m 10 m 33 65 m 380 m 750 m
2.5 mm² 8m 16 m 55 110 m 620 m 1,250 m
4.0 mm² 13 m 26 m 85 170 m 1,000 m 2,000 m
If increased inductive interference of the control cables is expected, shielded

cables with concentric conductors are to be used. The shield is effective only if
the concentric conductor at the start and end of the cable is correctly connected
to earth. Use of a buried earth electrode near the pole is the preferred solution.
If necessary, the foundation earth electrode or the pole earth can be used.
Connection to traction return current conductor is to be prevented.
7.2 Aids and tools

• Usual tools for contact lines and electrical installations
• Hexagon offset screwdriver with ball head (a/f 6) for M10 hexagon socket-
head bolts (at least 150 mm long)
• 17 mm socket wrench with extension
• Screwdriver, 4 x 0.8, for the spring terminals on the terminal blocks
• Water level
• Rubber hammer
• 200 mm long aluminum mounting sleeve (16 mm outer diameter, 12 mm
inner diameter)
• Hexagon offset screwdriver with ball head (a/f 5) (at least 150 mm long)
• Cordless screwdriver with adapter for square drive (3h) (see Figure
"Components of the mechanical actuating unit" on page 15)

Installation
7.3 Installation procedure

00
15
1270 - 1320
1140 - 1190
le:
po
at a
< 30°
t
cke
300 - 350
bra
the
g
tin
un
mo
400 - 500
300 - 350
40
L/2, max. 2000
L
45
< 2° < 2°
100 - 200
< 2° < 2°
800 - 850
switch in ON position
200
stroke
150
switch in OFF position

265
420
420
865
operated mechanism
8WL6243
100
860
4 x M10 dimensions in mm
Mounting dimensions with disconnector closed (example of 8WL6243, project-specific)

Installation

00
15
1270 - 1320
1140 - 1190
le:
po
at a
< 30°
t
cke
300 - 350
bra
the
g
tin
un
mo
400 - 500
300 - 350
40
L/2, max. 2000
L
45
< 2° < 2°
100 - 200
< 2° < 2°
800 - 850
switch in ON position
150
265 200
stroke
switch in OFF position
420
420
1360
420
operated mechanism
420
8WL6244
1100
6 x M10 100
dimensions in mm
Mounting dimensions with disconnector closed (example of 8WL6244, project-specific)

Installation
7.3.1 Mounting the casing on a pole
NOTE
Fasten the electromechanical operated mechanism to a pole or structure in such a way that the
distance between the ground and the bottom pair of screws of the casing support in the case of
the 8WL6243 type is about 860 mm. In the case of the 8WL6244 type, the distance from the
ground and the middle screw pair of the casing support should be about 1100 mm.
1. Remove the packing material from the operated mechanism and place the
mechanism down on its back.
2. Open the casing door and, at the four threaded bolts (2a), remove the caps
and hexagon nuts (2c), lock washers (2b) and insulator bushings (2d) to
detach the casing support.
3. Close the casing door, lift up the operated mechanism and remove the
casing support (2) from the casing's rear wall.
4. Take the casing support (2) and hold it with the opening pointing down
against the pole at the prescribed height. Align the casing support vertically
with the water level and mark the four or six drilling points for attaching the
support (see figures in Section 7.3).
5. Drill the holes for the M10 bolts in the pole and tap the M10 thread.
6. Firmly screw the casing support onto the pole with four or six M10 hexagon
socket screws (2f).
2a
2b
2c
2
2d
2f
2e
1f
1 casing 2c cap and hexagon nut

1f guide plate 2d insulating bush
2 casing support 2e Neoprene rubber seal
2a M10 threaded bolt 2f countersunk screws, M10x16
2b lock washer
Fastening on the pole (example 8WL6243)

Installation
7. Make sure that there is a Neoprene rubber seal (2e) for each threaded bolt
(2a). Replace missing seals.
8. Lift the operated mechanism onto the casing support. The guide plate (1f)
engages in the opening in the casing support.
9. Carefully push the operated mechanism onto the protruding threaded bolts
(2a) of the casing support.
10. Hold the operated mechanism firmly and open the casing door.
11. Onto the threaded bolts on the top right and bottom left, press one insulating
bush (2d) each into the baseplate (3e). Use the 200 mm mounting sleeve
to do this.
12. Fit one lock washer (2b) each and screw one hexagon nut each a few milli-
meters into the threaded bolts to fix the position of the operated mechanism.
13. Use a hexagon offset screwdriver with a ball head to remove the two M6
hexagon socket screws from the electric control unit (4) and allow the
control unit to hang down.
14. Use the crank handle to move the setting slide to the top end position.
15. Onto the threaded bolts (2a) on the top left and bottom right, press one insu-
lating bush (2d) each into the baseplate (3e). Use the 200 mm mounting
sleeve.
16. fit one lock washer (2b) for each threaded bolt (2a) and screw on one
hexagon nut each.
17. Then screw the operated mechanism onto the casing support with the four
M10 hexagon nuts.
18. Press one plastic cap (2c) each onto the hexagon nuts.
19. Again loosely screw on the electric control unit (4). This is unscrewed again
for better clamping of the external supply cable.
7.3.2 Establish the connection to the operating linkage.
6
3g
7
3s
1b
1b bellows 6 bolt
3g connecting clevis 7 split pin
3s M16 hexagon nut
Connecting clevis on the control rod

Installation
1. Pull the split pin (7) and remove the pin (6) out of the connecting clevis (3g).
2. Align the connecting clevis and the hinged piece of the operating linkage to
one another, plug the hinged piece into the connecting clevis and join both
of them with the bolt (6).
3. Lock the position of the connecting clevis with the M16 hexagon nut (3s).
4. Align the operating linkage so that is perpendicular to the operated mecha-
nism. Comply with the position deviation tolerances of ± 2°. Then secure the
bolt connection with the split pin (7).
7.4 Connecting the electric control unit

The cable diameter of the supply cable must not exceed 13 mm (see Section
12.4.1 "General electrical data/characteristic motor data" on page 52).
4r 4s 4u 4v 4w
4d
4e
4f
4h 4g
4d casing 4r terminal block X9 (optional)

4e terminal block X4 4s terminal block X8
4f terminal block X3 4u terminal block X7
4g terminal block X2 4v terminal block X6
4h terminal block X1 4w terminal block X5
Electric control unit
For the following work steps, pay attention to the corresponding assignment
diagrams for terminals (see Section 7.5 "Assignment diagram for terminals" on
page 36).
1. On the outside of the casing, loosen the nuts of the cable gland (1d) a little.
2. Push a sufficient length of cable through the corresponding cable gland.
3. Use a hexagon offset screwdriver with ball head (a/f 5) to remove the two
M6 hexagon socket screws from the electric control unit (4).

Installation
4. Remove the electric control unit from the front and mark the connectors
and, if applicable, the wires in compliance with the assignment diagram.
5. Remove the connectors from the terminal blocks.
6. Take the control unit (4) and fit the connectors onto the terminal blocks in
compliance with the assignment diagram.
7. Firmly screw down the electric operating unit with the two M6 hexagon
socket screws.
8. Secure the supply cable in the operated mechanism. Make sure there is
enough clearance from the moving parts. Fix the supply cable in place, if
necessary with cable ties.
9. On the outside of the casing, tighten the loosened nuts of the cable gland
(1d) again. The cable gland also provides tension relief.
If the specific project calls for the use of a PE when connecting the electric
control unit with 3-wire technology, this PE must be connected separately. Fit the
PE with a connecting eye suitable for M6 screws. Using a toothed lock washer,
fasten the PE to one of the upper M6 screws of the mounting plate (3t) (see
Figure "Actuating unit with motor" on page 19). The position of the mounting
plate and, therefore, the settings of the limit switches must not be changed as a
result of this work.

Installation
7.5 Assignment diagram for terminals

The assignment diagram is part of the adhesive label (see Section 12.7 "Adhe-
sive label" on page 55) that is located on the inside of the casing door.
7.5.1 Terminal assignment diagram for 230 V AC operated mechanisms (4-wire technology)
Belegungsplan für Klemmen
8WL6243-0S
Connection diagram for terminals vor Ort anschließen
Connection on site
Türschalter Endschalter EIN Endschalter AUS

Door switch Position switch ON Position switch OFF Sicat DMS
X5 X6 X7 X8
4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
(blau / blue)
GND
(braun / brown)
Signal +
L+
(weiß / white)
Option
potenzialfreier Kontakt
potential-free contact
PE
Message of the door switch
Meldung Türschalter
Befehl AUS (L1)

Befehl EIN (L1)
Command OFF
Command ON
Message OFF
Message OFF
230 V AC (L1)
Meldung AUS
Meldung AUS
Message ON
Message ON
Meldung EIN
Meldung EIN
M
N
6 5 4 3 2 1 4 3 2 1 2 1
X4 X2 X1
Terminal assignment diagram for 230 V AC operated mechanisms (4-wire technology)

Installation
7.5.2 Terminal assignment diagram for 230 V AC operated mechanisms (3-wire technology)
8WL6253-0S
Connection on site
Endschalter EIN Endschalter AUS

Position switch ON Position switch OFF
X6 X7
4 3 2 1 4 3 2 1
Befehl AUS (L1)

Befehl EIN (L1)
Command OFF
Command ON
M
N
4 3 2 1 2 1
X2 X1
Terminal assignment diagram for 230 V AC operated mechanisms (3-wire technology)
7.5.3 Terminal assignment diagram for 24 V DC and 60 V DC operated mechanisms

8WL6243-4S

Connection on site

X5 X6 X7 X8
4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
(braun / brown)
Signal +
(blau / blue)
(weiß / white)
L+
GND
Option
Meldung Türschalter (U+)
Meldung AUS (U+)
Meldung EIN (U+)
Versorgung (U+)
Befehl AUS (U+)
Versorgung (U-)
Befehl EIN (U+)
Command OFF
Message OFF
Message OFF
Command ON
Message OFF
Meldung AUS
Meldung AUS
Power supply
Power supply
Message ON
Message ON
Message ON
Meldung EIN
Meldung EIN
6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 2 1
X4 X3 X2 X1
Terminal assignment diagram for 24 V DC and 60 V DC operated mechanisms

Installation
7.6 Cable adapter (optional) for 3-wire and 4-wire technology

A cable adapter (8WL6256-7p) can be used to simplify the electrical connection
procedure for 3-wire and 4-wire technology.
However, this cable adapter must be ordered separately (see Section 12.5
"Spare parts and accessories" on page 54).
7.7 Connecting the floating contacts

External electrical connection of the floating contacts must be established
according to the requirements of the project. A maximum wire cross-section of
2.5 mm2 can be connected to the terminals. For electrical connections, analo-
gously perform the assembly steps detailed in Section 7.4 "Connecting the
electric control unit" on page 34. Also pay attention to Section
4.5 "Electric control" on page 16 (not applicable to 230 V AC circuit with 3-wire
technology).

Commissioning
8 Commissioning
WARNING
Death, severe bodily injury and damage to the motor-operated mechanism can occur if you fail to
observe the warnings and precautionary measures indicated in these operating instructions and
on the product itself.
When commissioning the operated mechanism, test the complete switching

installation. The switching installation is operable when the tests with the
operated mechanism were successful in compliance with its intended purpose
(see Section 8.2 "Operated mechanism" on page 40).
8.1 Disconnector and operating linkage

The following conditions must be met:
• The contact blades and the arcing horns must be able to move freely
without any obstruction.
• The prescribed end positions of the disconnector must be reached.
• When the disconnector is closed, the distance (dimension X) between the
spacer sleeve and the contact blade must comply with the operating instruc-
tions of the disconnector used (see Figure "Example set of contact of the
closed 3 kV DC disconnector 8WL6134" on page 39).
dimension X
contact spring
contact blade
spacer
Example set of contact of the closed 3 kV DC disconnector 8WL6134
Make sure that the operating linkage is properly connected to the operated
mechanism and the disconnector.

Commissioning
8.2 Operated mechanism

Carry out the tests on the operated mechanism when it is ready for use. A
detailed description of how the operated mechanism functions can be found in
Section 5 "Function" on page 18.
8.2.1 Test of manual operation
1. Open the casing door of the operated mechanism.

2. Set the mode selector switch (4c) to "0" and thus off to rule out electrical
actuation of the operate mechanism.
3. Fit the crank handle (5) onto the square drive (3h) and fully turn the crank
handle in one direction. Execute a complete stroke of 200 mm in this way.
4. Observe the movements of the control rod (3f) in the operated mechanism,
in the operating linkage and at the disconnector up to the end position.
5. If you detect any defects, they must be rectified before any further actions
are carried out.
6. Turn the crank handle in the other direction and proceed as described in
steps 4 and 5.
7. If you do not detect any defects, perform at least three complete manual
actuating cycles in order to test the proper function of the disconnector,
control rod and operated mechanism. The test is considered successful
when all switching operations have been performed without any problems.
are carried out.
9. Prepare the operated mechanism for testing in the electric mode. Remove
the crank handle from the square drive (3h).
8.2.2 Testing the electromechanical function
Local control of the operated mechanism

1. Leave the door of the casing open.
2. Set the mode selector switch (4c) on the electric control unit with local
control (4) to "1".
3. Press the "EIN/ON" pushbutton (4m). This triggers the pulse for the oper-
ating process for closing the disconnector.
4. Press the "AUS/OFF" pushbutton (4i). This triggers the pulse for the oper-
ating process for opening the disconnector.
5. Observe the motion sequences of the actuating unit in the operated mech-
anism, in the operating linkage and on the disconnector and also the light
signals of the LEDs in the pushbuttons (4m) and (4i).
are carried out.

Commissioning
7. If you do not detect any defects, perform at least five actuating cycles in
order to test the proper function of the disconnector, linkage and operated
mechanism. The test is considered successful when all switching opera-
tions have been performed without any problems.
are carried out.
9. Leave the mode selector switch on in the "1" position.
10. Close the casing door.
Remote control of the operated mechanism
NOTE
Do not carry out the function check of remotely controlled operation of the operated mechanism
until manual and electric local operation on the operated mechanism has been tested success-
fully.
11. Establish communication with the control center.

12. Ask the control center to operate the operated mechanism remotely.
13. Observe the movements at the opertaing linkage and at the disconnector.
14. Ask the control center to inform you about the incoming signals regarding
the end position of the disconnector. The incoming signals in the control
center must agree with the status of the disconnector.
are carried out.
16. If you do not detect any defects, ask the control center to perform at least
three remote-controlled actuating cycles in order to test the proper function
of the disconnector, linkage and operated mechanism. The test is consid-
ered successful when all switching operations have been performed without
any problems.
NOTE
The operated mechanism is operable when operability has been successfully tested in the
system.

Operation
9 Operation
9.1 Remote-controlled electrical operation

For electrical remote control of the operated mechanism, the following condi-
tions must have been met at the operated mechanism:
• the crank handle must be removed from the square drive (3h)
• the mode selector switch (4c) is in the "1" position
• the door of the casing is closed
When you open the casing door, depending on the variant the remote control
command is suppressed or a door status signal is issued by the door contact to
the telecontrol system. Other functions, such as blocking of external remote
operating commands, must be implemented by the operator.
NOTE
Pay attention to deviating behavior in the case of operated mechanisms with temporary power
supply (see Section 5.3 "Electrical part" on page 20).
9.2 Electrical local control

Electrical local control performed directly at the operated mechanism is primarily
intended for installation and maintenance purposes. The door of the operated
mechanism casing must be opened in order to gain access to the control
elements.
1 4c
0
4z
4m EIN/ON
AUS/OFF
4i
4c mode selector switch, lockable 4m pushbutton switch (red), EIN/ON

4i pushbutton switch (green), AUS/OFF 4z switch lock
Control elements on the control module
For electrical local control of the operated mechanism, the following conditions
must have been met at the operated mechanism:
• the casing door is open

Operation
• the crank handle is not on the square drive (3h)

• the position of the disconnector is indicated by the constantly illuminated
LED in the corresponding pushbutton (e.g. LED in the green pushbutton (4i)
is lit - the disconnector is open).
• the ON or OFF remote control commands are suppressed by the use of the
door signal outside the operated mechanism (only for 24 V DC and 60 V DC
operated mechanisms).
Switching
For instructions regarding switching processes, see the tabular action descrip-
tions.
Issue the ON or OFF switching command by briefly pressing (at least 0.5 s) one
of the pushbutton switches (4i) or (4m) on the local controls. This activates the
motor of the actuating unit and switching (disconnector opening/closing) is
executed. The control rod moves in the corresponding direction. The constantly
illuminated LED in the corresponding pushbutton indicates that the disconnector
has reached its end position. Intermediate positions are not indicated.
Closing the disconnector
Action Procedure Result
ON command • Green LED in the OFF • Control rod has stopped in

button goes off top end position
• Control rod moves outwards • Red LED in the ON button
• Disconnector is closed lights up
• Disconnector is in closed
Pushbutton switch (red) position
pressed for at least 0.5 s
Opening the disconnector
Action Procedure Result
OFF command • Red LED in the ON button • Control rod has stopped in
goes off bottom end position
• Control rod moves inwards • Green LED in the OFF
• Disconnector is opened button lights up
• Disconnector is open
Pushbutton switch (green)
pressed for at least 0.5 s

Operation
9.3 Local manual operation

Manual control of the operated mechanism is intended for installation and main-
tenance purposes and for cases of damage or power failure. For mechanical
local control of the operated mechanism, the following conditions must have
been met at the operated mechanism:
• the casing door is open
• the crank handle is on the square drive (3h) (see Figure "Components of
the mechanical actuating unit" on page 15)
NOTE
Note that if the mode selector switch has been switched off, the position of the disconnector is no
longer indicated by the LEDs or sent to the telecontrol system. Visually check the position of the
disconnector before you initiate any switching operation.
Move the crank handle (5) as described in Section "Operation with crank
handle" on page 19. End cranking at the stop position. In this case, the cam (3i)
has pressed the appropriate limit switch (4i) or (4m) and the operating lever (3p)
in the Maltese-cross gear has reached its position on the setting slide (3k).
9.4 Safeguarding the operated mechanism against electrical switching

Disconnectors on poles are to be secured against uncontrolled switching in
certain operating situations (e.g. during maintenance work). Set the operated
mechanism's mode selector switch (4c) to the "0" position. Press the lock (4z)
on the mode selector switch and use a suitable padlock (maximum bow
diameter 4 mm) to secure this position. Close the casing door. Use a semi-profile
lock barrel in the swivel lever lock (1a) to secure the closed operated mecha-
nism.

Maintenance
10 Maintenance
DANGER
When in operation, the disconnector carries dangerous levels of electrical voltage. Before
performing repair work, pay attention to the necessary protective measures detailed in Section 2.4
"Safety requirements" on page 8.
ATTENTION
Open the door of the operated mechanism casing and turn the mode selector switch (4c) to the
"0" position before you start any work on the operated mechanism.
NOTE
As part of the contact line system, the operated mechanism is subject to scheduled maintenance
which must be organised, carried out and documented by the operator of the system. Please
remember that the electromechanical operated mechanism forms part of a switching system and
cannot be considered as a separate entity.
10.1 Inspection
Interval Activity
Every two years • Visually determine the condition of the operated
mechanism, the operating linkage and the
disconnector and determine adequate lubrica-
tion of the worm and bevel gearing inside the
operated mechanism.
• Manually open or close a switch that is not often
used. Do this several times and check the
movement visually.
• Manually open or close a switch locally that is
not often used. Do this several times and check
the movement visually and the indicated
signals.
After a short-circuit current has flowed • On the applicable current-carrying disconnec-
tors, check that the sets of contacts are properly
closed
Shortened inspection interval (define • For a frequently actuated switchgear (approx.
depending on operating requirements) 1,000 switching cycles per year)
Inspection of an operated mechanism should include the following:

• Connection to the operating linkage at the connecting clevis
• Condition of the bellows
• Mechanical movements of the control rod and gearing
• Adequate lubrication of the worm and bevel gearing
• Seal around the casing
• ventilation pipe for dirt deposits
• Functioning of the swivel lever lock and, if provided, the semi-profile lock
barrel.

Maintenance
Make sure that any detected defects are rectified.
10.2 Maintenance
Any faults detected during the inspection must be rectified.
Interval Activity
Every six months • Check of functions with at least one
switching cycle by remote control
Every two years • Check that the mechanical fixing and
connection elements are securely seated.
Tighten any loose connections.
As required • Replace the ventilation pipe if it shows
signs of externally recognizable soiling.
• Grease the worm and bevel gearing
NOTE
Greasing the copper contacts on the disconnector and the guide and connection elements on the
operating linkage improves switching of the disconnector. Disconnectors with graphite-coated
contacts must not be greased as otherwise the self-lubricating properties of the surface coating
will be negatively influenced.
10.2.1 Replacing the ventilation pipes
Replace the ventilation pipes if dirt deposits are visible from the outside.
1e
1c
1d
1c cable gland M16 (optional)

1d cable gland M25
1e ventilation pipe
Ventilation pipe on the casing (example 8WL6243)
1. Unscrew the ventilation pipe (1e) from the casing.

2. Take a new ventilation pipe and insert it.
3. Screw the ventilation pipe into the casing hand tight using the lock nut. Turn
the ventilation pipe so that the slots in the side of the lock nut are over the
oblong hole in the pipe. This enables air to enter and any condensation to
drain away.

Maintenance
10.3 Corrective maintenance

NOTE
Only use parts approved by the manufacturer.
During corrective maintenance, rectify all the defects discovered in order to

ensure that the operated mechanism functions correctly. For the designations
and order numbers for spare parts, please see Section 12.5 "Spare parts and
accessories" on page 54.
Repairs
In the event of faults in the electric control unit, replace it as detailed in Section
"Replacement of the electric control unit" on page 47. It is only permissible to
replace the complete module.
If there are defects in other parts of the electric control and on the mechanical
operated mechanism, remove the complete operated mechanism in accordance
with Section 11.1 "Removing the operated mechanism from a pole or structure"
on page 48 and return the complete operated mechanism for repair in consulta-
tion with the Siemens office near you.
NOTE
Whenever an operated mechanism is replaced, replace the three Neoprene rubber seals (2e) on
the bolts (2a) of the casing support (2).
Replacement of the electric control unit

In the event of disruptions in the electric control unit (4), it must be replaced
completely.
1. Use a hexagon offset screwdriver with a ball head (a/f 5) to unscrew the
complete electric control unit (4) on the two fastening brackets (4k) and (4n)
from the baseplate (3e) and from the mounting block of the worm
gearing (3d).
2. On the electric control unit (4), remove all connectors from the terminal
blocks.
3. Mark the wire assignments.
4. Take a new complete electric control unit (4). Reconnect the terminals on
the terminal blocks in compliance with the terminal diagram (see Section
7.5 "Assignment diagram for terminals" on page 36).
5. Fasten the electric control unit (4) on the two fastening brackets back onto
the baseplate (3e) and mounting block of the worm gearing (3d).
6. Carry out a function test (see Section 8 "Commissioning" on page 39).

Disassembly
11 Disassembly
DANGER
Risk of fatal injury through high voltage at the electrical systems.
Observe the warnings and safety notes in these operating instructions.
11.1 Removing the operated mechanism from a pole or structure

1. Open the casing door of the operated mechanism.
2. Set the mode selector switch (4c) on the electric control unit with local
switching to the "0" position.
3. Mechanically disconnect the operated mechanism from the operating
linkage at the connecting clevis (3g).
4. Use a hexagon offset screwdriver with a ball head to remove the two M6
hexagon socket screws from the electric control unit (4) and allow the
control unit to hang down.
5. Remove the supply cable's wires from the applicable terminal blocks on the
electric control unit.
6. Undo the appropriate cable gland (1d), pull the supply cable out of the
casing and secure the cable's end.
7. Use the crank handle to move the setting slide to the top end position.
8. Remove the plastic caps (2c) from the four M10 hexagon nuts of the
threaded bolts (2a) and unscrew the hexagon nuts. Press the operated
mechanism onto the casing support to prevent falling over.
9. Hold the operated mechanism firmly and close the casing door.
10. Pull the operated mechanism downwards at an angle to the front and away
from the threaded bolts. Leave the guide plate (1f) in the opening of the
casing support (2).
11. Then lift the operated mechanism away from the casing support and place
it on the rear wall.
12. If necessary, detach the casing support (2) from the pole.

Disassembly
11.2 Dismantling the operated mechanism
6, 7
3g
3s
9
1b
10
1d
1b bellows 6, 7 bolt, split pin

1d bush 9 clamp
3g connecting clevis 10 clamp
3s M16 hexagon nut
Disassembling the operated mechanism into its individual parts
Open the casing door and first use the crank handle (5) to move the control rod
into its extended position.
1. Remove the split pin (7) and bolt (6) from the connecting clevis (3g) and
unscrew the connecting clevis and the M16 hexagon screw (3s) from the
control rod.
2. Undo the clamps (9) and (10) and remove the bellows (1b).
3. Remove the complete actuating unit with motor (3) by undoing the fastening
screws on the baseplate from the casing. Lift the actuating unit with motor
(3) out of the casing at an angle.
4. Remove the electric control unit (4) from the actuating unit with motor (3)
and undo the internal cable connections.
5. Unscrew the limit switches (4a) and (4b) (M4 hexagon socket-head bolts)
and remove the electrical connections.
6. Remove the motor from the actuating unit.
7. Continue dismantling the actuating unit as far as this makes sense.
8. Remove all detachable parts from the casing.
9. Pass on the dismantled signal parts for recycling or disposal according to
material groups.
11.3 Recycling and disposal

The operated mechanisms have been made from materials that can be recycled
or properly disposed of without harming the environment.

Disassembly
To ensure that the operated mechanisms can be recycled, they must be in a

condition that corresponds to their intended use. Separate the materials and
function parts appropriately. Components that cannot be recycled must be
disposed of correctly.
Where appropriate, separate the materials according to what they are made of
in accordance with local stipulations.
We can assist you with recycling and disposal. Please feel free to contact your
local Siemens representative, especially in cases of doubt about the separation
of materials.

Technical Data
12 Technical Data
12.1 Order No.

Designation Supply voltage Order No.
Electromechanical operated mechanism, 230 V AC 8WL6243-0
GRP casing, short 60 V DC 8WL6243-4
24 V DC 8WL6243-6
GRP casing, short
3-wire technology without local controls
GRP casing, long 8WL6244-0G
60 V DC 8WL6244-4
24 V DC 8WL6244-6
12.2 General data

Designation Type Value
Dimensions (length x width x height with [mm] 8WL6243 850 x 225 x 233
casing support) 8WL6244 1360 x 225 x 233
Weight with casing support [kg] 8WL6243 38.5
8WL6244 46
Switching frequency per minute 3 switching cycles
Permissible ambient temperature [°C] -25 to +50
Installation Altitude [m] 2000 above sea level
Color of casing RAL 6009 (fir green)*
Degree of protection of the casing in IP54
accordance with IEC 60529
Hole diameter in the switch lock of the [mm] 5.5
mode selector switch for padlock
* 8WL6244-0G RAL 9007(gray); Please enquire about other colors.

Technical Data
12.3 Mechanical data

Designation Value
Setting force in the end positions* [kN] ≥ 4.0
Setting force, half switching distance* [kN] ≥ 2.5
Stroke speed when disconnector* is being closed [mm/s] 40...66
Switching time (0.8 to 1.1 rated voltage UN) [s] 3 to 5
Stroke [mm] 200
Smallest pole that can be used HE-A 220
Casing support fastening with M10x16 hexagon socket- 4 ea. (8WL6243)
head bolts (EN ISO 10642) 6 ea. (8WL6244)
Operated mechanism fastening on the casing support Four each
- Neoprene rubber seal, Ø30x10 mm (1 mm thick)
- Insulating bush
- Washer 10.5 DIN 125-A2
- Hexagon nut M10 DIN 934-A4,
- Cap, a/f 17
* Information for an ambient temperature of 20° C
12.4 Electrical data

12.4.1 General electrical data/characteristic motor data
Designation Value
Nominal voltage [V] AC 230 (50 - 60 Hz)
[V] DC 24 / 60
Motor voltage tolerance 0.8 to 1.1 UN
Rated current during switching [A] 2 A at 230 V AC
7.5 A at 60 V DC
20 A at 24 V DC
Rated current during readiness/for own requirement* [mA] ≤ 25
Maximum continuous current for each signal [mA] 100
Operating mode of the motor in accordance with S3, 10 %
EN60034-1
Degree of protection of the motor in accordance with IP40
IEC 40050
Maximum diameter of supply cable [mm] 13
Maximum connectable wire cross-section [mm²]
- Terminal block X2 10 rigid
g(power supply (ON command/OFF command) 6 flexible
- Terminal block X3 ((ON signal(OFF signal) 2.5
- Terminal block X4 (door switch signal) 2.5
* Information for ambient temperature of 20 °C; increase dependent on external use of ON/OFF
signals and door signals by the operator or control center

Technical Data
Designation Value
Additional floating contacts for each end position *** 1 NO (Normally Open)
Maximum permissible voltage [V] 250
Maximum permissible current [A] AC 2.5**
DC 0.5**
Maximum wire cross section that can be connected to [mm²] 2.5
terminals
- Terminal block X4 (floating contacts)
** Please enquire about other values

*** For mechanisms with a permanent power supply
12.4.2 Commands and signals
Designation Operated mechanism

8WL6243-6 8WL6243-0 8WL6243-7
8WL6243-4 8WL6244-0
8WL6244-6 8WL6244-0G
8WL6244-4
Duration of the ON / OFF [s] min. 0.5 min. 0.5
control pulse
Potential of the ON / OFF [V] +24/+60 230 230
control pulses when end position
reached
Continuous potential of the [V] +24/+60 Generation,
ON / OFF control signals transfer of signals by relay control
system in the external actuating unit
Continuous potential of the [V]
door contact signal (additional
- door open 0 - contact optional)
- door closed +24/+60 -

Technical Data
12.5 Spare parts and accessories

Designation Order No. Dimensions
Electric control unit with local controls 8WL6256-7H (230 V 4- 130 x 106 x 105
(length x width x height) wire technology)
8WL6256-7M (60 V DC)
8WL6256-7N (24 V DC)
Electric control unit without local controls 8WL6256-7A (230 V, 130 x 106 x 105
(length x width x height) 3-wire technology)
Cable adapter (for 3-wire and 4-wire technology) 8WL6256-7P approx. 1000 mm
Adhesive label (depending on type of mecha- approx. 190 x 120
nism), notes on operation, terminal assignment
diagram
- 8WL6243-0 / 8WL6244-0 / 8WL6244-0G 8WL6243-0S
- 8WL6243-4 / 8WL6244-4 8WL6243-4S
- 8WL6243-6 / 8WL6244-6 8WL6243-6S
- 8WL6243-7 8WL6253-0S
Crank handle 8WL6256-6
Mounting clip for crank handle 8WL6256-61PA
(two parts required)
Bolt (DIN 43161) 8WL1104-2 M16x40
Split pin 8WL1115-1 5x28
Bellows 8WL6257-2A
Cable gland on request M25 / M16
Breather pipe complete with flat sealing ring 8WL6257-2B M25x1.5
Plastic caps (black) 8WL6252-4E a/f 17
Neoprene rubber (1 mm thick) 8WL6252-4D DM25x10x1
Grease for worm gearing and bevel gearing on request
Casing support 8WL6258-1a (short)
8WL6258-2a (long)
Semi-profile lock barrel in compliance with on request
DIN EN 18252
Adapter for square drive for crank handle on request
(when using a cordless screwdriver)
12.6 Standards
Title Contents
IEC 60038 Nominal voltages
EN 50110-1 Operation of electrical installations
EN 60529 Degrees of protection provided by enclosures (IP code)
EN 50122-1 Railway applications - Fixed installations
Protection provisions relating to electrical safety and earthing
EN 50122-2 Railway applications - Fixed installations
Protective provisions against the effects of stray currents caused
by d.c. traction systems
EN 50125-1 Railway applications - Environmental conditions for equipment
EN 60034-1 Operating modes of motors

Technical Data
12.7 Adhesive label

Adhesive label on the casing door inside with the following information:
• Note on operation with the crank handle
• Assignment diagram for terminals
• Note on electrical connection locally
12.7.1 Operated mechanism 8WL6243-0 / 8WL6244-0 / 8WL6244-0G

(230 V AC; 4-wire technology)
Order number 8WL6243-0S
Achtung / Attention
Vor dem Benutzen der Handkurbel Hauptschalter auf "0" stellen.
Put the main switch on "0" before using the crank-handle.
Bedienung des Schalterantriebs mit Handkurbel

Operation of the disconnector with crank-handle
Handkurbeldrehrichtung
Rotation direction of
the crank-handle
EIN AUS
ON OFF
Kurbel bis Anschlag drehen
Turn the crank-handle
until it stops
Trennschalter geschlossen Trennschalter offen

Closing disconnector Opening disconnector

8WL6243-0S

Connection on site

X5 X6 X7 X8
4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
(blau / blue)
GND
(braun / brown)
Signal +
L+
(weiß / white)
Option
PE
Befehl AUS (L1)

Befehl EIN (L1)
Command OFF
Message OFF
Message OFF
230 V AC (L1)
Command ON
Meldung AUS
Meldung AUS
Message ON
Message ON
Meldung EIN
Meldung EIN
M
N
6 5 4 3 2 1 4 3 2 1 2 1
X4 X2 X1

Technical Data
12.7.2 Operated mechanism 8WL6243-7 (230 V AC; 3-wire technology)
Achtung / Attention

the crank-handle
EIN AUS
ON OFF
until it stops

8WL6253-0S
Connection on site
Endschalter EIN Endschalter AUS

Position switch ON Position switch OFF
X6 X7
4 3 2 1 4 3 2 1
Befehl AUS (L1)
Befehl EIN (L1)
Command OFF
Command ON
M
N
4 3 2 1 2 1
X2 X1

Technical Data
12.7.3 Operated mechanism 8WL6243-6 / 8WL6244-6 (24 V DC) and

8WL6243-4 / 8WL6244-4 (60 V DC)
Achtung / Attention

the crank-handle
EIN AUS
ON OFF
until it stops

8WL6243-4S
Connection on site

X5 X6 X7 X8
4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
Signal +
(braun / brown)
(blau / blue)
(weiß / white)
L+
GND
Option
Meldung Türschalter (U+)
Meldung AUS (U+)
Meldung EIN (U+)
Befehl AUS (U+)
Versorgung (U+)
Befehl EIN (U+)
Versorgung (U-)
Command OFF
Message OFF
Message OFF
Message OFF
Command ON
Meldung AUS
Meldung AUS
Message ON
Message ON
Power supply
Power supply
Message ON
Meldung EIN
Meldung EIN
6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 2 1
X4 X3 X2 X1

Siemens AG
Industry Sector
Mobility Division
Mozartstraße 33b
91052 Erlangen
Germany
electrification.mobility@siemens.com
www.siemens.com/mobility/
electrification
Sicat 8WL6243/8WL6244
Operating Instructions / Version 1.0.0
A6Z00032010184 / Status: 2011-04-18

ANEXO B: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE AISLADORES DE SECCIÓN

s
Lightweight Section Insulator Sicat 8WL5545

for Overhead Contact Line Systems
Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
Copyright © Siemens AG 2002 - 2008. All rights reserved.

The group Transportation Systems of the Siemens AG has established and maintains for the
scope
Project Planning, Aquisition, Engineering, Procurement, Production, Assembly, Commissioning
and Service of Products, Systems and Services in the fields of Rail Automation, Electrification,
Locomotives, Trains, Mass Transit, Bogies, Turnkey Systems and Integrated Services
an integrated quality, safety, health and environmental management system in conformity with the
standards:
ISO 9001:2000
ISO 14001:2004
OHSAS 18001:1999
Certification was issued by the DNV Zertifizierung und Umweltgutachter GmbH and confirmed by
regular audits.
If you require additional copies of these operating instructions, please order from the responsible
Siemens sales office, stating the title and the following document number:
A6Z08110337684
Issued by:
Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
P.O. Box 32 40
91050 Erlangen
Germany
E-Mail: techcom.el.mobility@siemens.com
© Siemens AG 2002 - 2008
NOTE
The reproduction, transmission or use of this document or its contents is not permitted without express written au-
thority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a
utility model or design, are reserved.
Sicat® is a registered trademark of Siemens. The other names appearing in this documentation may be trade names,
the use of which by third parties for their own purposes may infringe the rights of the respective owners.
2 / 40 Sicat 8WL5545 / Operating Instructions / Version 3.2.2 / A6Z08110337684

Table of contents
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Sources of danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Tests and standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.1 Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3.2 Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.1 Transport conditions ................................................ 15
5.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.1 Clamping the contact wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Installation of suspension ............................................ 21
6.4 Assemble lightweight section insulators ................................. 22
6.4.1 Lightweight section insulator with one insulating rod . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4.2 Lightweight section insulator with two insulating rods . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Adjust lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sicat 8WL5545 / Operating Instructions / Version 3.2.2 / A6Z08110337684 3 / 40

7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Disassembly ...................................................... 31
7.2 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.1 Inspection ........................................................ 32
8.2 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8.2.1 Rotate insulating rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2.2 Cleaning the insulating rod ........................................... 34
8.3 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.3.1 Replace runners with arcing horns ..................................... 34
8.3.2 Replace insulating rods on the lightweight section insulator . . . . . . . . . . . . . . . . . . 36
8.3.3 Replace the insulating rod in the catenary wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1 Lightweight section insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.1.1 Lightweight section insulator for nominal voltage up to 3 kV DC . . . . . . . . . . . . . . . 37
9.1.2 Lightweight section insulator for nominal voltage 15 kV AC . . . . . . . . . . . . . . . . . . 37
9.1.3 Lightweight section insulator for nominal voltage 25 kV AC . . . . . . . . . . . . . . . . . . 38
9.2 Suspension (Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.4 Spare parts ....................................................... 39
9.5 Accessories and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General
1 General
These operating instructions are valid for the standard version of the product Sicat® 8WL5545 as
from model year 2006.
The operating instructions (according to IEC 62079:2001) are intended to make any personnel
familiar with the product.
WARNING
Death, serious physical injury and damage to property can occur.
During the operation of electrical equipment, certain parts of the equipment are inevitably energised at dangerous
electrical voltages.
Observe the safety regulations and warnings included in these operating instructions and on the product. Read these
operating instructions completely before installing this product. Keep these operating instructions ready to hand so
that you can refer to important information at all times.
A correct and safe operation of the product can be guaranteed only after suitable transport, proper storage, erection,
assembly, commissioning and careful maintenance.
NOTE
In the interests of clarity, these operating instructions do not contain all detailed information for all types of the product
and cannot take all conceivable conditions for the erection, operation and maintenance into account.
If you require further information, or if special problems arise, that have not been referred to sufficiently in the oper-
ating instructions, the necessary information can be requested through the local Siemens branch office.
We also draw attention to the fact that the contents of these operating instructions do not represent a part of an earlier
or existing agreement, warranty or legal relationship, nor do they alter the such.
All obligations on behalf of Siemens are based upon the respective purchase contract, which also contains the
complete and exclusively applicable warranty conditions. These contractual warranty conditions are neither
extended nor limited by the explanations given in these operating instructions.

Safety
2 Safety

These operating instructions contain warnings based on signal words in order to indicate the
degrees of danger.
Such warning notices can also be utilised in the form of sign boards or as stickers attached to the
product.
Symbol SIGNAL WORD
Meaning ...
Danger in the context of these operating instructions and the warning notices on the products
themselves, means that death or serious physical injury will occur, if the corresponding
safety measures are not obeyed.
Warning in the context of these operating instructions and the warning notices on the products
themselves, means that death or serious physical injury can occur, if the corresponding
safety measures are not obeyed.
Attention in the context of these operating instructions and the warning notices on the products
themselves, means that a light physical injury or damage to property can occur, if the
corresponding safety measures are not obeyed.
Note in the context of these operating instructions is an important information related to the
product or to the respective section of the documentation, to which special attention is
to be drawn.

Safety
2.2 Intended use
WARNING
Use of the product for purposes that are not intended can cause death, serious physical injury, considerable damage
to property and environmental pollution.
Use the product only for its intended purpose (see also section "Purpose and use" on page 9).
The use complies with the intended purpose if:
• the product is operated in accordance with the agreed terms of delivery and the stated tech-
nical specification, and
• any supplied devices and special tools are used exclusively for the intended purpose and in
accordance with the appropriate instructions in these operating instructions.
All other methods of use are forbidden unless explicit written agreement has been issued by
Siemens AG.

• the transport,
• the operation,
In addition, all persons performing the installation, commissioning, operation and maintenance of
the product must also possess qualifications and experience in the following basic skills:
• commissioning methods and commissioning procedures,
• first aid.
Please refer to national regulations (e. g. BGV A 3 in Germany, EN 50110 in Europe).

Safety

Instruct the personnel regularly on the currently applicable rules and regulations, the generally
applicable accident prevention regulations and legally binding safety instructions.
Irrespective of these, the following five safety rules according EN 50110-1:2004 apply:
NOTE
Before carrying out any work, do the following:
• Isolate the plant
• Secure against being switched on
• Make sure there is no residual voltage in the plant
• Earth and short-circuit the plant
• Cover or safeguard live parts
Use personal protective equipment as specified by national accident prevention regulations (in
Germany BGV A 1 or BGR 189-199).

If the specified requirements and conditions have not been obeyed or the safety instruction have
not been followed, then dangers are threatened by:
DANGER
Risk of fatal injury through high voltage at the electrical system.
Observe the warnings in these operating instructions and on the product.

Purpose and use
3 Purpose and use

Lightweight section insulators are used not only to divide the overhead contact lines into different
switching and feeder sections but also to isolate these sections from each other electrically.
The lightweight section insulators can be employed for electrical separation of the overhead
contact line between the main tracks as well as between the main tracks and sidings, for section-
alizing and for phase or system isolation gaps in combination with earthed and neutral overhead
contact line sections. Thanks to their excellent arc-extinguishing properties, lightweight section
insulators can also be installed wherever high voltage differentials exist between switchgear.
The Sicat 8WL5545 series lightweight section insulators are used in mass transit and mainline
systems. Depending on the pantographs and overhead line types used, they can be passed by
electric-powered trains running at a maximum speed of up to 200 km/h.
ATTENTION
Install the lightweight section insulator for mass transit (variant 8WL5545-7A/-8A) only in a conventional catenary
overhead line system. Suspension with two triangular droppers is necessary for lightweight section insulators.
The lightweight section insulator is primarily intended for installation on straight sections of track as otherwise it could
be subject to increased wear.

Design
4 Design
4.1 General
The lightweight section insulator consists of the following main components:
1 2 3a 4 3b 5 2 1
Lightweight section insulator with one insulating rod and for one contact wire
1 2 3a 4 3b 2 1
Lightweight section insulator with two insulating rods and for two contact wires
1 contact wire dead-end clamp 3a runner with arcing horn (short) 4 insulating rod
2 suspension strap 3b runner with arcing horn (long) 5 rail web*
* There are no rail webs at the variants 8WL5545-7A , 8WL5545-8A and 8WL5545-8AC
The insulating rods are arranged at the level of the contact wire so that no bending moments occur
on the lightweight section insulator. The pantograph can slide over the insulating rods at those
points where the air clearances are.
Spare parts and accessories can be exchanged quickly and easily as a result of the modular
design and the attachment method used.

Design
4.2 Tests and standards

The tests of the lightweight section insulators have been carried out in accordance with the
following standards:
Mechanical test:
• DIN VDE 0216:1986
• EN 50119:2001
Electrical test:
• IEC 61109:1992
• IEC 60071-1:1993
• IEC 60383-1:1993
• IEC 60060-1:1989
4.3 Variants
4.3.1 Lightweight section insulator
Lightweight section insulators are available in the below-mentioned designs (see table).
They vary in:
• the number of insulating rods and the resulting maximum operating load
• the length of insulating rods, the corresponding creepage distance and the resulting permitted
nominal voltage
• the use of rail webs
• the number and distance of contact wires to be connected
Number of Max. perm. Number of Nominal voltage Nominal voltage Nominal voltage
insulating rods operating load contact wires to up to 3 kV DC 15 kV AC 25 kV AC
be connected
1 15 kN 1 – 8WL5545-0A 8WL5545-3A
2 30 kN 1 8WL5545-7A 8WL5545-1A 8WL5545-4A
2 30 kN 1 – – 8WL5545-4AC
2 30 kN 1 – – 8WL5545-4AD
2 30 kN 2 8WL5545-8A – 8WL5545-2A
2 30 kN 2 8WL5545-8AC – –

Design
4.3.1.1 Lightweight section insulator with two insulating rods

L3
H
L2
B
C
L1
Lightweight section insulator for two contact wires
Dimensions of the lightweight section insulator

Variant Sicat 8WL5545
up to 3 kV DC 15 kV AC 25 kV AC
Type -7A -8A -8AC -1A -4A -4AC -4AD -2A
L1 [mm] 1725 1725 1725 2050 2490 2490 2688 2490
L2 [mm] 780 780 780 1170 1610 1610 1810 1610
L3 [mm] 700 700 700 1010 1450 1450 1654 1450
B [mm] 340 362 375 450 450 539 539 472
H [mm] 208 208 208 238 238 242 242 238
C [mm] – 28 40 – – – – 28
NOTE
The lightweight section insulators 8WL5545-1A, 8WL5545-2A, 8WL5545-4A, 8WL5545-4AC and 8WL5545-4AD
have rail webs (see Figure "Lightweight section insulator with one insulating rod and for one contact wire" on
page 10).

Design
4.3.1.2 Lightweight section insulator with one insulating rod

L3
H
L2
B
L1
Lightweight section insulator for one contact wire
Dimensions of the lightweight section insulator

Variant 8WL5545-0A 8WL5545-3A
15 kV AC 25 kV AC
L1 [mm] 2050 2490
L2 [mm] 1170 1610
L3 [mm] 1010 1450
B [mm] 450 450
H [mm] 238 238

Design
4.4 Suspension (Accessories)
NOTE
The suspension is not included in the scope of delivery of the lightweight section insulator and has to be ordered
separately.
The dead-end clamps (11) are not included in the scope of delivery of the suspension and have to be ordered sepa-
rately.
There are two suspension designs for corresponding nominal voltages (see table):
Type of suspension Order number Nominal voltage L [mm] A [mm] K [mm]
Suspension with catenary wire insulation
- for lightweight section insulator up to 3 kV DC 8WL5545-5A 3 kV DC 1600 ~ 700 1350
- for lightweight section insulator 15 kV AC 15 kV AC 1600 ~ 1010 1350
Suspension with catenary wire insulation
- for lightweight section insulator 25 kV AC 8WL5545-6A 25 kV AC 2000 ~ 1450 1750
- for lightweight section insulator 25 kV AC 8WL5545-6AD 25 kV AC 2200 ~ 1650 1950
L
K
14
ø25.6
20
max. 1940
12
min. 700
A
19
27
9
8 7 11
132
centre of contact wire
Suspension
7 end fitting
8 insulating rod of the suspension
9 turnbuckle
11 dead-end clamp
12 dropper wire
14 rod pulley
L length of insulating rod
A distance between the dropper wires
K min. creepage distance

Transport and storage
5 Transport and storage
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport. Do not lift or carry one-
sidedly or by means of the insulating rod. Carry the lightweight section insulator holding both suspension brackets
at the same time.
The means of transport to and at the installation site must be suited to the transportation with
respect to construction and load capacity.
The notices on the packing regarding weight, lifting and transport are to be observed.
5.2 Packing
The lightweight section insulators are delivered in a standard packaging.

The shipment must be checked immediately on receipt for damage and for completeness based
on the delivery notes.
NOTE
If the consignment is damaged, the scope and cause of the damage is to be established, documented in writing and
reported to the supplier without delay. The forwarding agent is to be enlisted to record the facts if transport damage
has occurred. A written record is essential for damage claims.

Installation
6 Installation
WARNING
In order for the lightweight section insulator to be operated safely, it must be mounted and commissioned properly
by qualified personnel in accordance with the warnings in these operating instructions.
Failure to comply can result in death, serious injury or considerable damage to property.
6.1 Preparatory work
ATTENTION
Install the lightweight section insulator for mass transit (variant 8WL5545-7A/8A) only in a conventional catenary
overhead line system. Suspension with two triangular droppers is necessary for lightweight section insulators.
The lightweight section insulator is primarily intended for installation on straight sections of track as otherwise it could
be subject to increased wear.
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport.
Do not lift or carry one-sidedly or by means of the insulating rod.
Carry the lightweight section insulator holding both suspension brackets at the same time.
Please observe the following before installing the section insulator:

• Wherever possible, the section insulator should be installed in a location that is in a straight
span between one third and half of the tension length in order to ensure for uniform uplift.
• The contact wire and catenary wire must be perpendicular to each other at the installation
location.
• Contact wire and catenary wire must lie in the mid-perpendicular to the plane of top of rails
(tolerance: ±50 mm).
NOTE
To facilitate transport the lightweight section insulator variants 8WL5545-0A/-1A/-2A/-3A/-4A are delivered without
the runners and rail webs fitted. These come packed together with the insulators and have to be fitted prior to instal-
lation and use.
NOTE
If you use the lightweight section insulator for an unworn AC-100 contact wire, the clamps for outer attachment of the
runners must be fixed in the round hole at the end of the runner.
For other contact wires, the clamp attachment for fixing the outer runners is provided at the elongated hole.
In order to clamp contact wires with nominal cross-sections greater than 120mm2, the factory-prepared mounting
position of the contact wire dead-end clamps (1) must be changed on the straps (6) (see Section 6.1.1 "Clamping
the contact wires" on page 17).

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

1a 6 4
Mounting height
1a clamping jaw
4 insulating rod
6 strap
Contact wires with nominal cross-section up to 120 mm²

To permit clamping of contact wires with nominal cross-sections of up to 120 mm², the clamping
jaws of the contact wire dead-end clamp (1a) are mounted in the factory in the outer four location
holes (see Figure "Position of the clamping jaw for contact wires with nominal cross-sections of
up to 120 mm²").
°
1,5
1a 6
Position of the clamping jaw for contact wires with nominal cross-sections of up to 120 mm²
1a clamping jaw
6 strap

Installation
Contact wires with nominal cross-section up to 120 mm²

In order to clamp contact wires with nominal cross-sections greater than 120 mm², position the
clamping jaws of the contact wire dead-end clamp (1a) one hole closer to the inside (see Figure
"Position of the clamping jaw for contact wires with nominal cross-sections greater than 120
mm²").
°
1,5
1a 6
Position of the clamping jaw for contact wires with nominal cross-sections greater than 120 mm²
1a clamping jaw
6 strap
1. Remove packing.
2. Screw a short and a long runner to the clamp for the outer attachment of the runners and to
the straps. The links for height adjustment are located on the outer sides of the runners. The
bolts of the links point inward and can be slide in the elongated hole of the runners.
3. Screw tight the rail webs between the runners at the variants 8WL5545-0A/-1A/-2A/-3A/-4A/
-4AC and -4AD.
4. Check the adjustment at the clamps (6a) for outer attachment of the runners.
6a
10

Installation
5. Fix the clamps for outer attachment of the runners in the round hole for unworn contact wire
AC-100 or in the elongated hole for all other contact wire types.
6. Establish and note the track superelevation or the gradient of the rail head contact plane at
the installation location of the lightweight section insulator.
7. Check whether the contact wire and the catenary wire lie in the mid-perpendicular to the rail
head contact plane. If not, correct the dimension (tolerance: ±50 mm).
8. Remove any existing kinks and twists in the contact wire.
9. Measure and note the contact wire height at the installation location of the lightweight section
insulator, starting from the installation platform or the mobile ladder.
10. Raise the contact wire in the installation area using the spring balance. You can find the lifting
force corresponding to the running speed in the following table.
Orientation values for contact wire lift

Maximum running speed [km/h] Lifting force for single contact wires [N] Joint lifting force for double
contact wires [ N]
20 80 120
100 100 140
160 120 160
200 150 200

Installation
11. Determine and note the contact wire height with the lifting force according to the Table "Orien-
tation values for contact wire lift" on page 19. The lower edges of the runners of the lightweight
section insulators should be at this height after installation. If you are using an installation plat-
form, use it as the reference point. The installation platform must then not be raised or lowered
until the lightweight section insulator has been installed.
hsection insulator
hcontact wire
6.2 Necessary tools

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

Installation
6.3 Installation of suspension
NOTE
The dead-end clamps (11) are not included in the scope of delivery of the suspension and must be ordered sepa-
rately.
1. Mount the dead-end clamps (11) suitable for the messenger wire on the end fittings (7) of the
insulating rod.
2. Calculate the length of the catenary wire section to be cut out.
ATTENTION
Bending the insulating rod in order to install it in the catenary wire will cause damage to the rod. Release the tension
in the catenary wire in the installation area only far enough to enable the insulating rod to be installed in the catenary
wire without having to bend it in the process. Avoid causing any distortion in the catenary system.
3. Install the tensioning device and release the tension in the catenary wire in the installation
area until the part of the messenger that is to be cut out starts to sag slightly. The catenary
system must not be distorted in the process.
4. Cut the catenary wire.

5. Assemble the suspension to the catenary wire insulation. Make sure that the catenary wire
does not become twisted. There must be no torsion forces acting on the insulating rod in the
catenary wire.
6. Check the connections between the insulating rod and the catenary wire.
7. Carefully load the catenary wire with the weight of the installed suspension and remove the
tensioning device.

Installation
6.4 Assemble lightweight section insulators
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport.
Do not lift or carry one-sidedly or by means of the insulating rod.
Carry the lightweight section insulator holding on the suspension straps at the same time.
6.4.1 Lightweight section insulator with one insulating rod
ATTENTION
Bending the insulating rod of the section insulator in order to install it in the contact wire will cause damage to the
rod. Release the tension in the contact wire in the installation area only far enough to enable the section insulator to
be installed in the contact wire without having to bend the insulating rod in the process. Avoid causing any distortion
in the catenary system.
1. Install the tensioning device with contact wire stringing grips and sling and release the tension
in the contact wire until it starts to curve upwards in the installation area.
2. Mark the interfaces of the contact wire on the contact wire. The lightweight section insulator
must be installed symmetrically under the suspension. Look in the table in Section 4.3.1.2
"Lightweight section insulator with one insulating rod" on page 13 for the length of contact wire
to be cut out (L2). The contact wire must protrude inward beyond the inner edges of the two
dead-end clamps by approximately 120 mm.
m
m
0
12

Installation
3. Cut the contact wire.
4. Place the lightweight section insulator on the contact wire symmetrically to the insulating rod
in the catenary wire.
5. Hook the ring hooks of the turnbuckles of the suspension into the suspension straps of the
lightweight section insulator.
6. Install both contact wire dead-end clamps of the lightweight section insulator on the contact
wire. Ensure that you tighten the M10 screws of the contact wire dead-end clamps from
outside inwards using two double-ended ring spanners.
7. Tighten the screws two times with a suitable torque wrench, allowing at least one minute to
pass after each time. The tightening torque is MA = 60 Nm.

Installation
8. Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening
torque is MA = 43 Nm.
6a
9. Retighten the screws on the contact wire dead-end clamps (1) three times to a torque
of 60 Nm, allowing at least one minute to pass after each time.
10. Retighten the screws on the clamps (6a) for outer attachment of the runners once more to a
torque of 43 Nm.
m
m
0
12
11. Lock the nuts on the clamps (6a) for outer attachment of the runners.
12. Bend the end section of the contact wire (120 mm) few millimetres upwards.
13. Remove the tensioning device and contact wire stringing grips. The lightweight section insu-
lator is then loaded with the contact wire tensile force.
15. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section
insulator" on page 27.

Installation
6.4.2 Lightweight section insulator with two insulating rods
1. Place the lightweight section insulator on the contact wire symmetrically to the insulating rod
in the catenary wire.
2. Hook the ring hooks of the turnbuckles of the suspension into the suspension straps of the
lightweight section insulator.
3. Install both contact wire dead-end clamps of the lightweight section insulator on the contact
wire. Ensure that you tighten the M10 screws of the contact wire dead-end clamps from
outside inwards using two double-ended ring spanners.
4. Tighten the screws two times with a suitable torque wrench, allowing at least one minute to
pass after each time. The tightening torque is MA = 60 Nm.
5. Install both clamps (6a) for outer attachment of the runners to the contact wire. The tightening
torque is MA = 43 Nm.
6a

Installation
6. Retighten the screws on the contact wire dead-end clamps three times to a torque of 60 Nm,
allowing at least one minute to pass after each time.
7. Retighten the screws on the clamps (6a) for outer attachment of the runners once more to a
torque of 43 Nm.
8. Lock the nuts on the clamps (6a) for outer attachment of the runners.
9. Cut the central contact wire section off in such a manner that approximately 120 mm of the
contact wire remains behind the contact wire dead-end clamp.
m
m
0
12
10. Bend the end section of the contact wire a few millimetres upwards.
12. Adjust the lightweight section insulator as described in Section 6.5 "Adjust lightweight section
insulator" on page 27.

Installation
6.5 Adjust lightweight section insulator
NOTE
Complete all installation and adjustment work on the entire tensioning section before you adjust the lightweight
section insulator.
Install the components which influence the height of the lightweight section insulator, such as shunt straps, before
you adjust the lightweight section insulator.
If the lightweight section insulator has to be short-circuited temporarily by means of a shunt strap, install the shunt
strap before you adjust the lightweight section insulator. In doing so, maintain a minimum distance of 3 m ahead of
and behind the lightweight section insulator both on the contact wire and on the catenary wire. Lead the shunt strap
over the lightweight section insulator in order to bring the strap into the area of the catenary wire.
Adjust the height of the lightweight section insulator as measured in Section 6.1 "Preparatory
work" on page 16, by adjusting the suspension as follows:
1. Adjust the suspension roughly at the Primodur clamps. Release the nuts at the Primodur
clamps, move the wire and tighten the nuts.
2. Carry out the fine adjustment of the suspension at the turnbuckles.

3. Set the position of the runner lower edge of the runner transversely to the track, parallel to the
track superelevation established in Section 6.1 "Preparatory work" on page 16 or the gradient
of the rail head contact plane.
The height of the outer runner ends is permanently set for unworn standard contact wire (AC-
100) by the way the clamps (6a) are attached in the round hole. For worn or other contact
wires, adjust the height of the outer runner ends by using the elongated holes provided. For

Installation
this purpose, the clamps (6a) for outer attachment of the runners must be repositioned in the
elongated holes.
6a
round hole elongated hole
NOTE
The lower edges of the runners should be 4 mm below the lower edge of the end fitting of the insulating rod (see
Figure "Checking the adjustment "A"" on page 29). The transitions from the contact wire to the runners and from the
runners to the insulating rod should not show height differences.
The pantograph must be transferred smoothly to the runners and must not nudge against the runner ends. At the
same time, each contact strip of the pantograph must make constant contact with at least one runner.
4. Adjust the height of the runners parallel to the track:

Use a pencil to mark the position of the link on the left and on the right.
Loosen the screws on the links and move the links to one side.
(Moving the link laterally by one millimetre corresponds to 0.5 mm adjustment in the height of
the lower edge of the runner).
5. Tighten the screws on the links slightly.

6. Check the position of the runners transversely to the track so that they are parallel with the
plane of top of rails.
7. Place a spirit level across the bottom of the runners in the area of the clamping plates. Check
the adjustment "A" (see Figure "Checking the adjustment "A"" on page 29). The adjustment
"A" is 4 mm for all types.
8. In case of a deviation, reset this adjustment accordingly.

Installation
13a
detail X
14 X
A = 4 mm
15 B
Checking the adjustment "A"
3 runner 13a clamping plate of the end fitting

4 insulating rod 14 Measuring tool
4a end fitting of the insulating rod 15 spirit level
A Adjustment between bottom of clamping plate (13a) and bottom of runners (B)
B Bearing surface for measuring device after spirit level has been placed across bottom of runners
9. Test the passage characteristics of the lightweight section insulator by passing a pantograph
over the insulator (if present on the multiple purpose vehicle). The pantograph must be trans-
ferred smoothly to the runners. The pantograph must not strike the inner or the outer ends of
the runners.
Passing the lightweight section insulator with a pantograph
10. Tighten all screws of the links with a torque spanner with a torque of MA = 43 Nm.
11. Tighten the counter nuts to secure the turnbuckles.

Installation
12. Secure the turnbuckles additionally with a piece of wire.
13. Adjust the droppers in front of and behind the lightweight section insulators so that they are
tight, but do not change the height of the lightweight section insulator.

Disassembly
7 Disassembly
7.1 Disassembly
NOTE
The lightweight section insulator insulating rods can be damaged by incorrect transport. Do not lift or carry one-
sidedly or by means of the insulating rod. Carry the lightweight section insulator holding at the suspension straps at
the same time.
1. Release the tension in the contact wire, and thus in the section insulator as well, with the aid
of a tensioning device with contact wire stringing grips and sling (see Section 6.4.1 "Light-
weight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the catenary wire and thus the insulating
rod of the suspension in the installation area only far enough to enable the connections to the catenary wire to be
undone, the insulating rod removed and replaced with a new one without having to bend the new insulating rod in
the process. Avoid causing any distortion in the catenary system.
2. Disassemble the suspension of the suspension straps of the lightweight section insulator.
3. Disassemble the lightweight section insulator.
4. Assemble a new lightweight section insulator or place a section of contact wire with contact
wire splices into the space.
5. Remove the tensioning device and contact wire stringing grips.
6. If a new lightweight section insulator is not to be assembled, release the tension in the
catenary wire with the tensioning device, catenary wire stringing grips and sling.
7. Disassemble the suspension.
8. Insert a new piece of catenary wire.
9. Remove the tensioning device and catenary wire stringing grips.
7.2 Disposal and recycling

The lightweight section insulators have been produced out of materials which for the most part can
be disposed of in an environmentally friendly manner and properly recycled.
A prerequisite for the disposal is that the lightweight section insulator is in a condition correspon-
ding to correct and proper usage. Parts which cannot be recycled must be correctly disposed of.
We can provide help with disposal and recycling. In this respect, please contact your local
Siemens company.

Maintenance
8 Maintenance
WARNING
Death or severe bodily injury can occur due to high electric voltage. De-energize the overhead line system before
performing maintenance work or safeguard the maintenance location or the overhead line system in accordance with
the regulations.
8.1 Inspection
Inspect the lightweight section insulator after every short-circuit in the relevant area. Inspect the
lightweight section insulator for possible damage after short-circuits caused by pantograph passes
into earthed sections. If evidence of overheating is visible, replace the suspension wires.
The contact forces of passing pantographs are higher in DC systems than in AC systems. Higher
runner wear must therefore be expected.
Type of system AC system DC system
Inspection interval • every two years or • yearly or

after commissioning • after about 200.000 pantograph passages • after about 100.000 pantograph passages
Part to be inspected Inspection purpose Evaluation

Runner (3a), (3b) Determine degree of - Erosion at the arcing horns
wear - Remaining cross-sectional area of the runners in the areas of
greatest wear (see Figure "Areas of greatest runner wear" on
page 35)
Contact wire dead-end Check bolted Use a torque wrench to check the bolted connections (tightening
clamp (1) connections torque MA = 60 Nm).
Insulating rod (4) Determine degree of Dirt deposits impair the insulating effect. Clean the insulating rod
contamination during maintenance work.
Determine degree of If the wear zone has been used up, rotate the insulating rod as
wear required or replace if necessary (see Figure "Insulating rod wear"
on page 33).
Suspension Check bolted Check the connections between the insulating rod and the
connections catenary wire
8.2 Preventive maintenance

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

Maintenance
8.2.1 Rotate insulating rod
ATTENTION
The insulating rod will be damaged if you release it at only one end and then rotate it. Observe the following handling
instructions. Rotate the insulating rod simultaneously at both ends.
The insulating rods can be rotated up to three times, which ensures even wear and maximum
service life. The rotation must be performed when the wear is ≥ 2.5 ≤ 3.5 mm of the nominal dia-
meter (see Figure "Insulating rod wear" on page 33.
The diameter of an insulating rod is 20 mm.
wear zone
dimension in mm
17.5 ...16.5
17.5 ...16.5
15...13
15...13
20
turned 180° turned 90° turned 180° replace
Insulating rod wear
13a
Rotate insulating rod
13a clamping plate of the end fitting

Maintenance
in the contact wire and thus in the section insulator in the installation area (see Section 6.4.1
"Lightweight section insulator with one insulating rod" on page 22).
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the contact wire and thus in the section
insulator in the installation area only far enough to enable the insulating rod to be disconnected from the section insu-
lator, rotated and tightly secured again without having to bend the insulating rod in the process. Avoid causing any
distortion in the catenary system.
2. Loosen the screws at both clamping plates (see Figure "Rotate insulating rod" on page 33),
in which the insulating rod is fixed.
3. Rotate the insulating rod simultaneously at the ends into the desired position.
4. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm.
5. Replace the insulating rods when the wear of material is roughly 3 mm on all sides.
8.2.2 Cleaning the insulating rod
If necessary, remove dirt deposits from the insulating rod using water mixed with a commercially
available detergent. Do not use any implements with sharp edges, e.g. machining tools, which
might damage the PTFE coating on the insulating rod.
8.3 Corrective maintenance
ATTENTION
Only original spare parts supplied by Siemens AG may be used for maintenance work.
In the event of a repair, contact your Siemens agency.
8.3.1 Replace runners with arcing horns
NOTE
If track superelevation is present, the gradient of the runners to each other transversely to the track is to be deter-
mined with a spirit level before removal and is to be taken into account during adjustment of the new runners.
ATTENTION
Damage can be caused to the lightweight section insulator by incorrect assembly.
Take note of the diagonal arrangement of the runners in asymmetrical lightweight section insulators.

Maintenance
Exchange the runners if due to arcing the dimension between lower edge of the runner and top
edge of the arcing horn is less than 100 mm or the remaining cross-section of the runners in the
areas of greatest wear has been worn down to 3 mm and therefore the necessary stability is no
longer ensured (see Figure "Areas of greatest runner wear" on page 35).
B
A
detail A detail B
100
3
dimensions in mm
wear zone
Areas of greatest runner wear
1. Remove the screws and the links for the height adjustment of the runners.
2. Remove the runners.
3. Fix the new runners.
4. Repeat the handling instructions 1 to 3 for the other three runners, if necessary.
5. Adjust the runners or the lightweight section insulator as described in Section 6.5 "Adjust light-
weight section insulator" on page 27.

Maintenance
8.3.2 Replace insulating rods on the lightweight section insulator
NOTE
The insulating rods can be damaged by incorrect transport. Always pick up an insulating rod with both hands and
carry it so that the weight of the insulating rod cannot cause it to sag in the middle.
in the contact wire and thus in the section insulator in the installation area (see Section 6.4.1
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the contact wire and thus in the section
insulator in the installation area only far enough to enable the insulating rod to be disconnected from the section insu-
lator and removed and a new one to be installed and tightly secured again without having to bend the new insulating
rod in the process. Avoid causing any distortion in the catenary system.
2. Loosen the screws at the ends of the clamping plates.

3. Remove the insulating rod.
4. Insert the new insulating rod.
5. Tighten the screws at the end fittings with a torque spanner twice with a torque of MA = 80 Nm.
8.3.3 Replace the insulating rod in the catenary wire
NOTE
The insulating rods can be damaged by incorrect transport. Always pick up an insulating rod with both hands and
carry it so that the weight of the insulating rod cannot cause it to sag in the middle.
in the catenary wire and thus in the suspension in the installation area (see Section 6.4.1
ATTENTION
Bending the insulating rod will cause damage to it. Release the tension in the catenary wire and thus the insulating
rod of the suspension in the installation area only far enough to enable the connections to the catenary wire to be
undone, the insulating rod removed and replaced with a new one without having to bend the new insulating rod in
the process. Avoid causing any distortion in the catenary system.
2. Remove the dropper wires from the insulating rod.

3. Disconnect the insulating rod from the wedge-type dead-end clamps of the catenary wire.
4. Fix the dropper wires to the new insulating rod.
5. Connect the insulating rod to the wedge-type dead-end clamps of the catenary wire.
6. Check the connections between the insulating rod and the catenary wire.
7. Remove the tensioning device.

Technical data
9 Technical data
9.1 Lightweight section insulator

9.1.1 Lightweight section insulator for nominal voltage up to 3 kV DC
Type / Order number 8WL5545-7A 8WL5545-8A 8WL5545-8AC

Nominal voltage DC [kV] 3 3 3
Clearance in air [mm] 60 60 60
Creepage distance [mm] 450 450 450
Weight [kg] 13.0 13.8 15.1
Maximum permissible operating load [kN] 30 30 30
Minimum failing load [kN] 90 90 90
Number of insulating rods 2 2 2
Number of contact wires 1 2 2
Contact wire distance [mm] – 28 40
Cross-section of contact wires
to be connected acc. to EN 50149 AC/BC-80 to 150, Cu-ETP
AC/BC-80 to 150, CuAg0.1
AC/BC-80 to 120, CuMg0.5
Other cross-sections of contact wires Ri161, Cu-ETP (British Standard 23)
CTHA-85/-120 (China Standard)
9.1.2 Lightweight section insulator for nominal voltage 15 kV AC
Type / Order number 8WL5545-0A 8WL5545-1A

Nominal voltage AC [kV] 15 15
Clearance in air [mm] 120 120
Creepage distance [mm] 760 760
Weight [kg] 13.0 14.9
Maximum permissible operating load [kN] 15 30
Minimum failing load [kN] 45 90
Number of insulating rods 1 2
Number of contact wires 1 1
Cross-section of contact wires to be connected
acc. to EN 50149 AC/BC-80 to 150, Cu-ETP
AC/BC-80 to 150, CuAg0.1
AC/BC-80 to 120, CuMg0.5
CTHA-85/-120 (China Standard)

Technical data
9.1.3 Lightweight section insulator for nominal voltage 25 kV AC
Type / Order number 8WL5545

-2A -3A -4A -4AC -4AD
Nominal voltage AC [kV] 25 25 25 25 25
Clearance in air [mm] 220 220 220 300 300
Creepage distance [mm] 1200 1200 1200 1200 1400
Weight [kg] 15.9 14.1 15.9 16.5 19.66
Maximum permissible operating load [kN] 30 15 30 30 30
Minimum failing load [kN] 90 45 90 90 90
Number of insulating rods 2 1 2 2 2
Number of contact wires 2 1 1 1 1
Contact wire distance [mm] 28 – – – –
Cross-section of contact wires to be connected
acc. to EN 50149 AC/BC-80 bis 150, Cu-ETP
AC/BC-80 bis 150, CuAg0.1
AC/BC-80 bis 120, CuMg0.5
CTHA-85/-120 (China)
9.2 Suspension (Accessories)

Type / Order number 8WL5545-5A 8WL5545-6A 8WL5545-6AD
For section insulator 8WL5545-0A/-1A/ 8WL5545-2A/-3A/ 8WL5545-4AD
-7A/-8A/-8AC -4A/-4AC
For nominal voltage DC [kV] 3 – –
AC [kV] 15 25 25
Maximum permissible operating load [kN] 30 30 30
Minimum failing load [kN] 90 90 90
Minimum creepage distance [mm] 1350 1750 1950
Weight [kg] 6.13 6.63 6.73
9.3 Materials
Part Material
Clamping fittings CuNiSi (Copper-Nickel wrought alloy)
Runners with arcing horns Copper
Insulating rods (section insulator) GRP (Glass-fiber reinforced plastic), PTFE
Insulating rods (suspension) GRP (Glass-fiber reinforced plastic), silicone
End fittings (suspension) stlSt (Stainless steel)
Turnbuckles stlSt (Stainless steel)
Rod pulley Polyamide, CuSn (Tin bronze)
Dropper wire 16f BzII (Bronze, strength grade II)

Technical data
9.4 Spare parts

Description Order number
Runner long for section insulator 25 kV 8WL5548-3B
Runner short for section insulator 25 kV 8WL5548-3D
Runner long for section insulator 25 kV (8WL5545-4AC) 8WL5548-3BC
Runner short for section insulator 25 kV (8WL5545-4AC) 8WL5548-3DC
Runner long for section insulator 25 kV (8WL5545-4DC) 8WL5548-3BD
Runner short for section insulator 25 kV (8WL5545-4DC) 8WL5548-3DD
Runner long for section insulator 15 kV 8WL5548-3F
Runner short for section insulator 15 kV 8WL5548-3H
Runner long for section insulator 3 kV 8WL5548-3K
Runner short for section insulator 3 kV 8WL5548-3M
Insulating rod for section insulator 25 kV (creepage distance 1200 mm) 8WL5548-0A
Insulating rod for section insulator 25 kV (creepage distance 1400 mm) 8WL5548-0H
Insulating rod for section insulator 15 kV 8WL5548-0B
Insulating rod for section insulator 3 kV 8WL5548-0C
Insulating rod for suspension 25 kV (creepage distance 1750 mm) 8WL5548-5CB
Insulating rod for suspension 25 kV (creepage distance 1950 mm) 8WL5548-5DD
Insulating rod for suspension 3 kV and 15 kV 8WL5548-5CC
9.5 Accessories and tools

Description Order number
Contact wire stringing grips 8WL7140-0
Sling 8WL7142-7

Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
P.O.Box 32 40
91050 Erlangen
Germany
electrification
Sicat 8WL5545
A6Z08110337684 / Status: 2008-11-20
Subject to change without prior notice!

ANEXO C: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE POLEAS

s
Tension Wheel Assembly up to 24 kN Sicat 8WL5078

for Tensioning Equipment in Overhead Contact Line Systems
Siemens AG
Industry Sector
Mobility Division
Copyright © Siemens AG 2011. All rights reserved.

The group Industry Sector, Mobility Division (I MO) of the Siemens AG has
established and maintains for the scope
Project Planning, Acquisition, Engineering, Procurement, Production, Assem-
bly, Commissioning and Service of Products, Systems and Services in the
Business Units Rail Automation, Rolling Stock and Complete Transportation
a management system in conformity with the standards:
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
Certification was issued by the DNV Zertifizierung und Umweltgutachter GmbH
and confirmed by regular audits.
If you require additional copies of these operating instructions, please order from
the responsible Siemens sales office, stating the title and the following
document number and version:
A6Z08111121403
Issued by:
Siemens AG
Industry Sector
Mobility Division
Mozartstraße 33b
91052 Erlangen
Germany
E-Mail: techcom.el.mobility@siemens.com
© Siemens AG 2011
NOTE
The reproduction, transmission or use of this document or its contents is not permitted without
express written authority. Offenders will be liable for damages. All rights, including rights created
by patent grant or registration of a utility model or design, are reserved.
Sicat® is a registered trademark of Siemens. The other names appearing in this documentation
may be trade names, the use of which by third parties for their own purposes may infringe the
rights of the respective owners.

Table of contents
1 General ............................................ 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Sources of danger .................................... 9
3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1 Tension wheel assemblies 8WL5078-0A, 8WL5078-0B and
8WL5078-0C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2.2 Tension wheel assemblies 8WL5078-1A, 8WL5078-1C and
8WL5078-1D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2.3 Tension wheel assembly 8WL5078-2 . . . . . . . . . . . . . . . . . . . . . . 14
4.2.4 Tension wheel assembly 8WL5078-3 . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Possible arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3.1 Tension wheel assemblies on pole or wall . . . . . . . . . . . . . . . . . . 16
4.3.2 Tension wheel assembly in the tubular steel pole . . . . . . . . . . . . . 17
4.4 Sensor 8WL5067-0 (optional) for Sicat CMS . . . . . . . . . . . . . . . . 18
5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.1 Tension wheel assembly without cabling (standard) . . . . . . . . . . . 19
5.2.2 Tension wheel assembly with fitted wires (optional) . . . . . . . . . . . 19
5.3 Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.1 Working equipment ................................... 20
6.1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.2 Tightening torque for hexagon bolts and nuts . . . . . . . . . . . . . . . 20
6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.1 Preliminary measures for the variants 8WL5078-0A, -0B, -0C,
-1A, -1C and -1D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.2 Preliminary measures for the variants 8WL5078-2 and
8WL5078-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.3 Winding wires to the tension wheel assembly . . . . . . . . . . . . . . . 22
6.3 Fitting the tension wheel assembly to the fixing elements . . . . . . 26
6.3.1 The 8WL5078-0A/-0B/-0C tension wheel assembly .......... 27
6.3.2 The 8WL5078-1A, -1C and -1D tension wheel assembly ...... 29
6.3.3 The 8WL5078-2 and 8WL5078-3 tension wheel assembly . . . . . 30
6.4 Connecting the tension wheel assembly to weight set and
catenary system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.1 Making the connection to the weight set . . . . . . . . . . . . . . . . . . . 33
6.4.2 Making the connection to the catenary system . . . . . . . . . . . . . . 34
6.5 Function test and readjustment on the tension wheel assembly . 35
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.1.1 Visual inspection ..................................... 37
7.1.2 Function test of the tension wheel equipment . . . . . . . . . . . . . . . 38
7.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Repairs following a fault in the overhead contact line ......... 39
7.3.1 Repairs following contact wire or catenary breakage . . . . . . . . . . 39
7.3.2 Repair following short-circuit with current flow through the tension
wheel equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.1 Disassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.2 Recycling and disposal ................................ 41
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.1 Order numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.2 Mechanical and electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.3 Material ............................................ 43

9.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.5 Accessories (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

General
1 General
These operating instructions are valid for the standard version of the product
Sicat® 8WL5078 as from model year 2011.
The operating instructions (according to IEC 62079:2001) are intended to make
any personnel familiar with the product.
WARNING
Death, serious physical injury and damage to property can occur.
Observe the warning notices in Section 2 "Safety" on page 7.
Observe the safety regulations and warnings included in these operating instructions and on the
product. Read these operating instructions completely before installing this product. Keep these
operating instructions ready to hand so that you can refer to important information at all times.
A correct and safe operation of the product can be guaranteed only after suitable transport, proper
storage, erec-tion, assembly, commissioning and careful maintenance.
NOTE
In the interests of clarity, these operating instructions do not contain all detailed information for all
types of the product and cannot take all conceivable conditions for the erection, operation and
maintenance into account.
If you require further information, or if special problems arise, that have not been referred to suffi-
ciently in the op-erating instructions, the necessary information can be requested through the local
Siemens branch office.
We also draw attention to the fact that the contents of these operating instructions do not represent
a part of an earlier or existing agreement, warranty or legal relationship, nor do they alter the such.
All obligations on behalf of Siemens are based upon the respective purchase contract, which also
contains the complete and exclusively applicable warranty conditions. These contractual warranty
conditions are neither ex-tended nor limited by the explanations given in these operating instruc-
tions.

Safety
2 Safety

These operating instructions contain warnings based on signal words in order to
indicate the degrees of danger.
Such warning notices can also be utilized in the form of sign boards or as
stickers attached to the product.
Symbol SIGNAL WORD

Meaning...
Danger in the context of these operating instructions and the warning

physical injury will occur, if the corresponding safety measures are
not obeyed.
Warning in the context of these operating instructions and the warning

physical injury can occur, if the corresponding safety measures are
not obeyed.
Attention in the context of these operating instructions and the warning

notices on the products themselves, means that a light physical
injury can occur, if the corresponding safety measures are not
obeyed.
Attention in the context of these operating instructions and the warning

notices on the products themselves, means that a damage to
property can occur, if the corresponding safety measures are not
obeyed.
Note in the context of these operating instructions is an important infor-

mation related to the product or to the respective section of the
documentation, to which special attention is to be drawn.

Safety
2.2 Intended use
WARNING
Use of the product for purposes that are not intended can cause death, serious physical injury,
considerable damage to property and environmental pollution.
Use the product only for its intended purpose (see also section 3 "Purpose and
use" on page 10).
The use complies with the intended purpose if:
• the product is operated in accordance with the agreed terms of delivery and
the stated tech-nical specification, and
• any supplied devices and special tools are used exclusively for the intended
purpose and in accordance with the appropriate instructions in these oper-
ating instructions.
All other methods of use are forbidden unless explicit written agreement has
been issued by Siemens AG.

• the operation,
In addition, all persons performing the installation, commissioning, operation
and maintenance of the product must also possess qualifications and experi-
ence in the following basic skills:
• commissioning methods and commissioning procedures,
• first aid.
Please refer to national regulations (e. g. BGV A 3 in Germany, EN 50110 in
Europe).


Safety
Instruct the personnel regularly on the currently applicable rules and regulations,
the generally applicable accident prevention regulations and legally binding
safety instructions.
Irrespective of these, the following five safety rules according to
EN 50110-1:2004 apply:
NOTE
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
Use personal protective equipment as specified by national accident prevention

regulations (in Germany BGV A 1 or BGR 189-199).

If the specified requirements and conditions have not been obeyed or the safety
instruction have not been followed, then dangers are threatening by:
DANGER
Risk of fatal injury through high voltage at the electrical system.
DANGER
Risk of fatal injury through railway vehicles during work in track area.
operator.
DANGER
Risk of fatal injury through work in heights on working platforms, ladders and poles.
operator.
ATTENTION
Risk of injury through falling and/or toppling parts and risk of trapping through moving parts.

Purpose and use
3 Purpose and use

Tension wheel assemblies are parts of tension wheel equipments in overhead
contact line systems. They are mounted at the end of a tension section. When
tension wheels are used for tensioning, the contact wire or catenary wire is
maintained at a constant tensile force, irrespective of variations in the wire or
cable lengths caused by temperature changes. This is necessary to maintain a
faultfree power transfer to the traction unit.
Tension wheel assemblies of the type 8WL5078 have a mechanical locking
system (latching device) which, in the case of a break in the contact wire or
catenary wire, prevents the weights used for applying tensile force from falling
onto the track, nearby pathways etc.. Subsequent damage to the overhead
contact wire system is prevented.
The type 8WL5078 tension wheel assemblies permit tensioning of movable
contact respectively catenary wires with a tensile force up to 24 kN.

Design
4 Design
4.1 General
There are two basic versions of the tension wheel assembly 8WL5078, one for
installation on open lines and one for lines where the installation conditions are
restricted. Which tension wheel assembly is selected for the corresponding
tension section of the overhead contact line system depends on the specific
project (see Section 4.2 "Variants" on page 11).
NOTE
Use only steel wires 8WL7090-0, 8WL7090-1C respectively 8WL7090-1G when rigging up the
tension wheel assembly. The special design enables these steel wires to withstand high alter-
nating bending stress and to provide a long service life.
The tension wheel assembly is supplied without wires. A description of how to

wind wire onto the wheel body is given in Section 6.2 "Preparation" on page 20.
As an option, the tension wheel assembly can also be supplied with the wire
wound on.
4.2 Variants
Tension wheel assembly 8WL5078
-0A -0B -0C -1A -1C / -1D -2 / -3
Basic version for open lines for narrow installation -
conditions
Mounting type on steel or concrete pole mounting on HE poles, in the
structures (e.g. inside tubular
tunnels) steel pole
Execution type with mounting support without with without -
for guide tube mounting mounting mounting
support for support for support for
guide tube guide tube guide tube
up to up to - up to - -
Ø 36 mm Ø 43.5 mm Ø 36 mm

Design
4.2.1 Tension wheel assemblies 8WL5078-0A, 8WL5078-0B and 8WL5078-0C
The design of the tension wheel assemblies is shown in Figure "Tension wheel
assembly 8WL5078-0A" on page 12. These tension wheel assemblies can be
used in tension sections on open sections of track. The weight set needed to
apply tensile force is arranged on the side of the wheel body facing away from
the pole. The tension wheel assemblies can be mounted on steel or concrete
poles with appropriate fixing elements. The fixing elements are not part of the
scope of supply of the tension wheel assemblies. The tension wheel assemblies
8WL5078-0A/-0B are fitted with a mounting support for the weight guide tube,
consisting of an angle (5) and strap (6).
The tension wheel assembly 8WL5078-0C does not have a mounting
support.
422
14
1
7
12
8, 9
470
75
3
498
11
225
1)
187 - 287 13
2)
Ø36
10
13a
5 6
dimensions in mm
1 wheel body 8, 9 M24 hexagon nut

2 swing lever 10 M24x70 hexagon bolt
3 suspension 11 M24 hexagon nut
4 latching plate 12 safety hoop
5 angle 13* steel wire 8WL7090-0
6 strap 13a* wedge-type dead-end clamp with special wedge
7 M24x70 hexagon bolt 14* steel wire with connecting fittings
8WL7090-1C (7.5 m)
* not part of the scope of supply of the tension wheel assembly
1) dependent of the diameter of weights
2) at tension wheel assembly 8WL5078-0B Ø43.5 mm
Tension wheel assembly 8WL5078-0A

Design
4.2.2 Tension wheel assemblies 8WL5078-1A, 8WL5078-1C and 8WL5078-1D
The design of the tension wheel assemblies is shown in Figure "Tension wheel
assembly 8WL5078-1A" on page 13. These tension wheel assemblies can be
used in tension sections where the space available for installation is restricted.
The weight set needed to apply tensile force is arranged on the side of the wheel
body facing the pole. The tension wheel assemblies can be mounted on HE
poles or brickwork/tunnel walls with appropriate fixing elements. The fixing ele-
ments are not part of the scope of supply for the tension wheel assemblies. The
tension wheel assembly 8WL5078-1A is fitted with a mounting support for the
weight guide tube, consisting of an angle (5) and a strap (6).
The tension wheel assemblies 8WL5078-1C and 8WL5078-1D do not have
a mounting support.
459
1 14
8, 9
75
470
3
498
11
225
10
4a
5
13
6 ø36 13a
1)
190 - 250 dimensions in mm
1 wheel body 7 M24x70 hexagon bolt

2 swing lever 8, 9 M24 hexagon nut
3 suspension 10 M24x70 hexagon bolt
4 bracket for latching plate 11 M24 hexagon nut
4a latching plate 13* steel wire 8WL7090-0
5 angle 13a* wedge-type dead-end clamp with special wedge
6 strap 14* steel wire with connecting fittings
8WL7090-1C (7.5 m)

1) dependent of the diameter of weights
Tension wheel assembly 8WL5078-1A

Design
4.2.3 Tension wheel assembly 8WL5078-2
The design of the tension wheel assembly is shown in Figure "Tension wheel
assembly 8WL5078-2" on page 14. The weight set needed to apply tensile force
is located in the tubular steel pole. The tension wheel assembly is installed at
the mounting parts in the tubular steel pole. The fixing elements are not part of
the scope of supply for the tension wheel assembly.
3 7 2 1
14
6
205
75
470
8, 9
4a
13
65 80 225
80 12
13a
dimensions in mm

3 suspension 12 M16x30 hexagon bolt (3x)
4 bracket for latching plate 13* steel wire 8WL7090-0
4a latching plate 13a* wedge-type dead-end clamp with special wedge
6 clevis 14* steel wire with connecting fittings
8WL7090-1C (7.5 m)

Tension wheel assembly 8WL5078-2

Design
4.2.4 Tension wheel assembly 8WL5078-3
The design of the tension wheel assembly is shown in Figure "Tension wheel
assembly 8WL5078-3" on page 15. The weight set needed to apply tensile force
is located in the tubular steel pole. The tension wheel assembly is installed at
the mounting parts in the tubular steel pole. The fixing elements are not part of
the scope of supply for the tension wheel assembly.
3 7 2 1
14a
6
205
150
8, 9
470
4a
13
65 80 225
80 12
13a dimensions in mm

3 suspension 12 M16x30 hexagon bolt (3x)
4 bracket for latching plate 13* steel wire 8WL7090-0
4a latching plate 13a* wedge-type dead-end clamp with special wedge
6 clevis 14a* steel wire with connecting fittings
8WL7090-1G (9.5 m)
Tension wheel assembly 8WL5078-3

Design
4.3 Possible arrangements

Tensioning equipment with tension wheel assemblies are suitable for separate
tensioning of contact wires or catenary wires.
4.3.1 Tension wheel assemblies on pole or wall
The following arrangements on the pole or wall are possible:

• individual
• parallel • above each other, offset

(possible for all variants) (possible for all variants)
>590 mm
a
a horizontal distance of the tension wheel assemblies ≥ 350 mm,

or diameter of weights + 150 mm
Tension wheel assembly 8WL5078-1A (example)

Design
• one in front of the other
8WL5078-0A 8WL5078-1A
8WL5078-0B 8WL5078-1C
8WL5078-0C 8WL5078-1D
> 590 mm
> 590 mm
b b
b horizontal distance of the tension wheel assemblies ≥ 350 mm,

or diameter of weights + 150 mm
NOTE
The minimum horizontal distance apply for the use of Siemens-supplied weights.
When using weights up to 300 mm diameter, the minimum horizontal distance between the weight
column or rotarybolt axes of the tension wheel suspension can be reduced to 350 mm.
4.3.2 Tension wheel assembly in the tubular steel pole
8WL5078-2 8WL5078-3
Tension wheel assemblies 8WL5078-2 and 8WL5078-3

Design
4.4 Sensor 8WL5067-0 (optional) for Sicat CMS

Tension wheel assemblies type Sicat 8WL5078-0A, -0B, -0C, -1A , -1C and -1D
in catenary or contact wire systems can be retrofitted with sensor 8WL5067-0
for Sicat® CMS.
Sicat CMS is designed for contactless monitoring of the catenary system. For
further details, please refer to the corresponding product documentation.
An example of the sensor arranged on the tension wheel assembly is shown in
the figure "Sensor arrangement on tension wheel assembly 8WL5078-0A" on
page 18.
Sensor arrangement on tension wheel assembly 8WL5078-0A

Transport and storage
5 Transport and storage

The transportation equipment to and at site must be of the correct type and have
the required load capacity for the equipment to be lifted. Note the weight infor-
mation, centre of gravity, lifting and transportation instructions on the packing.
5.2 Packing
5.2.1 Tension wheel assembly without cabling (standard)
The tension wheel assemblies are delivered in suitable packaging, for example
in skeleton container pallets or on Euro pallets. To prevent contact between the
tension wheel assemblies and damage of the zinc surface through transport
vibrations, cardboard or chip cushions (shrink- wrapped) are placed between
the assemblies.
NOTE
When you intend to transport the completely assembled tension wheels elsewhere, put them verti-
cally into crate pallets without intermediate excelsior layers respectively intermediate layers which
could stick to grease and bitumen.
5.2.2 Tension wheel assembly with fitted wires (optional)
The wires attached to the wheel body must be fixed firmly to the wheel body with
wire or adhesive tape for transportation.

On receipt of the delivery, check all items for damage and compare it with the
delivery note to make sure that the delivery is complete
NOTE
If the consignment is damaged, the scope and cause of the damage is to be established, docu-
mented in writing and reported to the supplier without delay. The forwarding agent is to be enlisted
to record the facts if transport damage has occurred.
A written record is essential for damage claims.
5.4 Storage
Protect the tension wheel assembly and, if applicable, the wires from dust and
heavy fouling.

Installation
6 Installation
6.1 Working equipment

6.1.1 Tools
• abrasive cutter
• tie wire, adhesive tape or similar fixing material
• spirit level
• rubber mallet
• vice with jaw protectors
• two ring and open-end spanners or ratchet spanner, size 19 and 36,
for each worker
• torque spanner for size 19 (torque range 10 - 200 Nm, 60 - 350 Nm)
• contact wire stringing grips, slings, ratchet puller
• thermometer
• tape measure at least 10 m long, folding meter
6.1.2 Tightening torque for hexagon bolts and nuts
Bezeichnung Tightening torque

M8 16 Nm
M12 56 Nm
M16 100 Nm
M20 180 Nm (only fix with a lock nut)
M24 250 Nm (only fix with a lock nut)
6.2 Preparation
6.2.1 Preliminary measures for the variants 8WL5078-0A, -0B, -0C, -1A, -1C and -1D
For transporting the tension wheel assembly, the wheel body (1) and the swing
lever (2) are bolted to the suspension (3). To facilitate mounting of the tension
wheel assembly, detach the wheel body and swing lever from the suspension.
Undo and remove the bolts (2a), (2b) and (2c) between the swing lever and
suspension (3) (see Figure "Bolted connection between suspension and swing
lever" on page 21) and place the wheel body and swing lever down separately
on a firm surface.
Remove the bolts at the top and bottom of the suspension (see Figure "Tension
wheel assembly 8WL5078-0A" on page 12). Undo and remove the hexagon
nuts (8), (9) and (11) of the hexagon bolts (7) and (10) and then pull the
hexagon bolts out of the suspension (3). Place all parts on a firm surface and
orderly arranged for mounting.

Installation
2b
2c
2a
2 swing lever 2c M20 hexagon nut

2a M20x150 hexagon bolt 3 suspension
2b washer 21
Bolted connection between suspension and swing lever
6.2.2 Preliminary measures for the variants 8WL5078-2 and 8WL5078-3
NOTE
Hinweis
The welded frame (5a) and flange (5b) for the tubular steel pole are not in the scope of delivery of
the tension wheel assembly.
For the installation of the tension wheel assembly, the tubular steel pole has to
be prepared in accordance with the project specifications (see Figure "Dimen-
sions of the mounting materials at the tubular steel pole" on page 22).
The following steps have to be performed:
• Assemble and prepare the welded frame (5a) and two flanges (5b).
• Determine the position of the cutout in the tubular steel pole for the welded
frame (5a).
• Make the cutout in the tubular steel pole and align the cutout with the
position of the contact wire to be tensioned (after installation, the steel wire
from the tension wheel assembly must be horizontally centered and laterally
parallel to both sides of the welded frame).
• Drill three holes with M16 threading for securing the bracket (4) in the
welded frame (5a).
• Weld the welded frame (5a) and flanges (5b) on and in the tubular steel
pole.
• Drill two ø21 mm holes in the tubular steel pole for securing the
suspension (3).

Installation
ø310 - 400
10
5b
16
ø21
A A
266 ± 0,5
205
800
5b
80
470
440 -1
5a
5 16
170 A-A
10
M16
50 50
310
10
dimensions in mm
40 40
5 tubular steel pole

5a welded frame
5b flange
Dimensions of the mounting materials at the tubular steel pole
6.2.3 Winding wires to the tension wheel assembly
NOTE
These instructions apply only to tension wheel assemblies supplied without the wires fitted.
For variants 8WL5078-1A/-1C/-1D/-2/-3 wind the wires in the opposite direction (E and F).

Installation
2
C
E 12
A cupal wire casing 1 wheel body

B slot 2 swing lewer
C wheel hub 12* safety hoop
D wheel axle
E* direction of rotation for winding wire onto the wheel hub (small diameter)
F* direction of rotation for winding wire onto the wheel diameter (large diameter)
* for variants 8WL5078-0A/-0B/-0C

Wheel body details
13 14/14a 15 16
13 8WL7090-0 steel wire 15 two pin clevis link (8WL1018-0)

14 8WL7090-1C steel wire with 16 equalizing pulley with straps (8WL5160-0 or
connecting fittings (7.5 m) pulley and guy clevis
(8WL2137-4 and 8WL5167-4)
14a* 8WL7090-1G steel wire with
connecting fittings (9.5 m)
* for variant 8WL5078-3

Arrangement of wires on the wheel body

Installation
6.2.3.1 Winding wire to the wheel diameter (weight suspension wire)
NOTE
Use only steel wires 8WL7090-0 when rigging up the tension wheel assembly.
The special design enables these steel wires to withstand high alternating bending stress and
provides a long service life. The steel wire, the 8WL1201-0 one-hole wedge, the wedge-type
dead-end clamp 8WL1180-7 and the special wedge 8WL1202-3 are not in the scope of delivery
of the tension wheel assembly and must be ordered separately.
For the following work steps, refer to Figures and "Bolted connection between
suspension and swing lever" on page 21 and "Arrangement of wires on the
wheel body" on page 23.
1. Measure the projected length of the rope and mark the splitting point.
2. Wind adhesive tape or tie wire around the steel wire to both sides of the
location of the cut in order to prevent the steel wire from splaying. The layer
of adhesive tape or tie wire must be thin enough to allow the steel wire to
be inserted into the cupal wire casing (A) on the wheel body.
3. Cut the steel wire (13) with an abrasive grinder.
4. Secure the swing lever (2) in a vice with jaw protectors. The wheel body
must rotate freely in the swing lever.
5. In the case of types 8WL5078-0A/-0B/-0C, remove the safety hoop (12)
from the swing lever (2).
6. Feed one end of the steel wire through the large opening in the wheel body
diameter and into the small opening of the cupal wire casing (A).
7. Pull this end of the wire through and, behind the wire casing, form it into a
loop of about 50 cm length.
8. Insert the one-hole wedge into this loop so that its largest radius is posi-
tioned in the loop.
9. Feed the loop with the one-hole wedge into the wire casing and tighten the
loop with the wedge with a firm tug. Secure the wedge by hitting it with a
rubber mallet.
10. Wind the steel wire up away from the wire casing (direction of rotation F)
tightly under tension and without twisting it, and secure it against unwinding.
NOTE
After winding wire onto the wheel hub, attach the wedge-type dead-end clamp (13a) for connec-
tion to the weights (see Section 6.2.3.3 "Mounting the wedge-type dead-end clamp on the weight
wire" on page 26).

Installation
6.2.3.2 Winding wire to the wheel hub (catenary connection)
NOTE
Use only steel wires 8WL7090-1C respectively 8WL7090-1G when rigging up the tension
wheel assembly.
The special design enables these steel wires to withstand high alternating bending stress and
provides a long service life. The steel wire with connecting fittings, the 8WL1018-0 two pin clevis
link and the equalizing pulley with straps (8WL5160-0) or pulley and guy clevis (8WL2137-4 and
8WL5167-4) are not included in the scope of delivery of the tension wheel assembly and must be
ordered separately.
For the following work steps, refer to "Bolted connection between suspension
and swing lever" on page 21 and "Arrangement of wires on the wheel body" on
page 23.
1. Take the steel wire (14) and mark it about 50 cm from its centre.
2. Lay the wire out flat and remove any twists in the wire.
3. Feed one end of the wire into the space between the wheel spokes
containing a slot (detail B). Pull the wire through up to the mark, place it into
the slot at that point and secure it to the spoke, e.g. with wire.
4. Place the ends of the wire into the grooves in the left and right wheel hubs
(detail C). Wind the wire onto the wheel hub in parallel from inside to
outside.
5. Tension the wire, rotate the wheel body in direction E and wind the steel wire
up away. Secure the wire on both sides against unwinding, e. g. with wire.
6. Take the pulley (16) and pull the split pin out of the pin of the pulley.
NOTE
As an alternative to the equalizing pulley with straps (8WL5160-0) you can use a pulley
(8WL2137-4) and guy clevis (8WL5167-4) for assembling at the steel wire.
7. Pull the pin out and take the pulley out of the straps respectively guy clevis.
8. Place the longer section of wire over the circumference of the pulley.
9. Position the pulley complete with wire in the straps or guy clevis and pull the
pin through the pulley.
10. Secure the connection to the split pin.
11. Take the two pin clevis link (15) and remove on one side the split pin and a
strap.
12. Push the thimbles of the wire ends (14) onto the pulley pins and press the
strap back onto the pins.
13. Secure the connection to the pins with split pins.
14. Use tie wire to fasten the guy clevis to the wheel body. Bear in mind that the
wire can jump out of the grooves if it is not fastened correctly.

Installation
15. Mount the safety hoop (12) at the types 8WL5078-0A/-0B/-0C on the swing
lever (2) again.
6.2.3.3 Mounting the wedge-type dead-end clamp on the weight wire

1. Take the wedge-type dead-end clamp (13a) and pull the end of the wire
through about 50 cm.
2. Form this end of the wire into a loop and pull it back through the dead-end
clamp.
3. Hold the special wedge in the loop and press the dead-end clamp over the
loop.
4. Pull the end of the wire tight. Secure the special wedge by hitting it lightly
with a rubber mallet.
6.3 Fitting the tension wheel assembly to the fixing elements

Requirements for the tension wheel assembly fixing elements for the variants
8WL5078-0A, -0B, -0C, -1A, -1C and -1D
NOTE
The fixing elements (17) and (18) and the adjusting strap (19) are not included in the scope of
delivery of the tension wheel assmbly. They must be ordered separately.
Please refer to Figures "Fixing elements and mounting clearances for the
8WL5078-0A/-0B/-0C tension wheel assemblies" on page 27 and "Fixing
elements and mounting clearances for the 8WL5078-1A/-1C/-1D tension wheel
assemblies" on page 29.
• Note the maximum material thickness for the fixing elements:
– fixing element (17): less than 13 mm
– fixing element (18) including adjusting strap (19): less than 30 mm
• The fixing elements must be sufficiently wide. If new tensioning equipment
is installed, the static calculations are to verifiably documented.
• The holes drilled in the upper and lower fixing elements for mounting the
suspension (3) must enable vertical alignment of the suspension.
• The distance between the inside edges of the fixing elements must not be
more than 500 +2 mm.
• The adjusting strap (19) must be provided in accordance with the project
stipulations (symmetrical or asymmetrical design).

Installation
6.3.1 The 8WL5078-0A/-0B/-0C tension wheel assembly
7 17 2
23
8, 9 1
2a, 2b, 2c
3 498
18
D
11
30
19
422 dimensions in mm
10
1 wheel body 8 M24 hexagon nut

2 swing lever 9 M24 hexagon nut (lock nut)
2a M20x150 hexagon bolt 10 M24x70 hexagon bolt
2b washer 21 11 M24 hexagon nut (lock nut)
2c M20 hexagon nut 17* upper fixing element
3 suspension 18* lower fixing element
4 latching plate 19* adjusting strap
7 M24x70 hexagon bolt (8WL5006-1A/-2A, depending on need)
* not included in the scope of delivery
Fixing elements and mounting clearances for the 8WL5078-0A/-0B/-0C tension wheel
assemblies
1. Mount the fixing elements (17) and (18) in accordance with the project stip-
ulations.
2. On the lower fixing element (18), mount an adjusting strap (19) in accor-
dance with the project stipulations for perpendicular adjustment of the
tension wheel assembly axle (see Figure "Adjusting strap at the lower fixing
element" on page 28).
3. Push the suspension (3) of the tension wheel assembly between the fixing
elements and align the holes in the parts in relation to each other.
4. Attach the suspension and the upper fixing element (17) using hexagon
bolt (7) and hexagon nuts (8). Tighten the hexagon nuts firmly but not too
tightly.

Installation
5. Then insert the hexagon bolt (10) through the holes in the adjusting
strap (19) and lower fixing element (18) and screw the hexagon screw into
the threaded hole of the suspension (3).
There should be a gap between the head of the screw and the adjusting strap.
It must be possible to move the suspension.
6. Lift the wheel body (1) with swing lever (2) to the height of the
suspension (3) and place the wheel body on the latching plate (4). Hold the
wheel body firmly in position.
7. Take a hexagon bolt (2a) with washer (2b). Push the hexagon bolt through
the holes of the swing lever and suspension. Fit a washer (2b) on the bolt,
screw on a hexagon nut (2c) and tighten it firmly but not too tightly.
It must be possible to move the swing lever on the suspension.
8. Adjust the tension wheel assembly in accordance with the project stipula-
tions.
NOTE
The wheel body must be aligned vertically and its teeth must engage with the latching plate (4)
when not tensioned. Check that it is vertical by placing a spirit level against the outer surface of
the wheel body. Tension wheel assemblies which are not vertical can be adjusted with the
adjusting strap (19).
9. Fix the tension wheel assembly in a vertical position by firmly tightening the
two bolts attaching it to the adjusting strap (19) (see Figure "Adjusting strap
at the lower fixing element" on page 28).
Detail X
18 11
19c
3
19b
19
10 19a
3 suspension 19 adjusting strap

10 M24 hexagon bolt 19a M16 hexagon bolt
11 M24 hexagon nut 19b washer 17
18 lower fixing element 19c M16 hexagon nut
Adjusting strap at the lower fixing element
10. Use locking nuts to secure the bolts in the fixing elements (17) and (18) and
in the swing lever (2).
NOTE
The bolts of the fixing elements (17) and (18) and of the swing lever (2) must be secured with nuts
in such a way that the tension wheel assembly can move horizontally around the longitudinal axis
and the swing lever can move vertically with the wheel body.

Installation
6.3.2 The 8WL5078-1A, -1C and -1D tension wheel assembly
459
7 17
23
1
2
8, 9
2a, 2b, 2c
3
+2
500
401
4
18
4a
11 30 225
19
5 dimensions in mm
10 6
1 wheel body 61) strap

2a M20x150 hexagon bolt 8, 9 M24 hexagon nut
2b washer 21 10 M24x70 hexagon bolt
2c M20 hexagon nut 11 M24 hexagon nut
3 suspension 17* upper fixing element
4 bracket for latching plate 18* lower fixing element
4a latching plate 19* adjusting strap
51) bracket (8WL5006-1A/-2A/-3A, depending on need)

1) not at type 8WL5078-1C/-1D
Fixing elements and mounting clearances for the 8WL5078-1A/-1C/-1D tension wheel
assemblies
1. Mount the fixing elements (17) and (18) in accordance with the project stip-
ulations.
2. On the lower fixing element (18), mount an adjusting strap (19) in accor-
dance with the project stipulations for perpendicular adjustment of the
tension wheel assembly axle (see Figure "Adjusting strap at the lower fixing
element" on page 28).
3. Undo the bolted connection between the strap (5) and angle (6) attached to
the mounting support for the guide tube and push the strap out of the
mounting area next to the lower fixing element.
4. Push the suspension (3) of the tension wheel assembly between the fixing
elements (17) and (18) and align the holes in the parts in relation to each
other.

Installation
5. Attach the suspension (3) and the upper fixing element (17) using hexagon
bolts (7) and hexagon nuts (8). Tighten the hexagon nuts firmly but not too
tightly.
6. Then insert the hexagon bolt (10) through the holes in the adjusting
strap (19) and lower fixing element (18) and screw the hexagon screw into
the threaded hole of the suspension (3).
There should be a gap between the head of the screw and the adjusting strap.
It must be possible to move the suspension.
7. Lift the wheel body (1) with swing lever (2) to the height of the
suspension (3) and place the wheel body on the latching plate (4a). Hold
the wheel body firmly in position.
8. Take a hexagon bolt (2a) with washer (2b). Push the hexagon bolt through
the holes of the swing lever and suspension. Fit a washer (2b) on the bolt,
screw on a hexagon nut (2c) and tighten it firmly but not too tightly.
It must be possible to move the swing lever on the suspension.
9. Adjust the tension wheel assembly in accordance with the project stipula-
tions.
NOTE
The wheel body must be aligned vertically and its teeth must engage with the latching plate (4a).
Check that it is vertical by placing a spirit level against the outer surface of the wheel body. Tension
wheel assemblies which are not vertical can be adjusted with the adjusting strap (19).
10. Fix the tension wheel assembly in a vertical position by firmly tightening the
two bolts attaching it to the adjusting strap (19) (see Figure "Adjusting strap
at the lower fixing element" on page 28).
11. Use locking nuts to secure the bolts in the fixing elements (17) and (18) and
in the swing lever (2).
NOTE
The bolts of the fixing elements (17) and (18) and of the swing lever (2) must be secured with nuts
in such a way that the tension wheel assembly can move horizontally around the longitudinal axis
and the swing lever can move vertically with the wheel body.
6.3.3 The 8WL5078-2 and 8WL5078-3 tension wheel assembly
For the installation of the tension wheel assembly in the tubular steel pole, first
remove the suspension (3) from the clevis (6) at the swing lever (2) (see Figure
"Removing the suspension from the clevis at the swing lever" on page 31).
1. Loosen and remove the two hexagon nuts (8, 9).
2. Pull the hexagon bolt (7) out of the clevis (6).
3. Store the parts in a safe location.

Installation
6 2
3
8, 9

3 suspension 8, 9 M24 hexagon nut
6 clevis
Removing the suspension from the clevis at the swing lever
NOTE
The arrangement for securing tension wheel assembly type 8WL5078-2 in the pole is shown as
an example (see Figure "Securing tension wheel assembly 8WL5078-2 in the tubular steel pole"
on page 32). Tension wheel assembly 8WL5078-3 is secured in identical fashion.
Depending on the internal diameter of the pole, prepare two spacer

bushings (11) and select two hexagon bolts (10) of an appropriate length for
securing the suspension (3) (see Figure "Securing tension wheel assembly
8WL5078-2 in the tubular steel pole" on page 32). This ensures that the weight
wire runs in the center of the tubular steel pole after the tension wheel assembly
is installed. Refer to the following table for the required values.
Pole internal diameter Length L Length H

of hexagon bolt (10) of spacer bushing (11)
[mm] [mm] [mm]
310 100 10
320 100 15
330 120 20
340 120 25
350 130 30
360 130 35
370 140 40
380 150 45
390 150 50
400 150 55

Installation
ø310 - 400
5b 6
10
2
1
L
H
view X
11
3
5a
550
5b
4a 5
5 80 X 12
dimensions in mm 50 50
1 wheel body 5a* welded frame

2 swing lever 5b* flange
3 suspension 6 clevis
4 bracket 10* M20xL hexagon bolt
4a latching plate 11* spacer bushing 30x4xH
5* tubular steel pole 12 M16x30 hexagon bolt (3x)
H Length of the spacer bushing (11)

L Length of the hexagon bolt (10)
Securing tension wheel assembly 8WL5078-2 in the tubular steel pole
4. Prepare the spacer bushings (11) according to the table.

5. Select the hexagon bolts (10) according to the table.
6. Take the suspension (3) and insert the hexagon bolts (10) through the
holes.
7. Place the spacer bushings (11) on the hexagon bolts (10).
8. Guide the suspension (3) between the flanges (5b) and insert the hexagon
bolts (10) into the holes at the tubular steel pole (5).
9. Secure the suspension (3) at the tubular steel pole using two M20 hexagon
bolts provided on site.
10. Install the bracket (4) in the welded frame (5a) using three hexagon
bolts (12).
11. Pick up the wheel body (1) and place the wheel body (1) on the latching
plate (4a).
12. Hang the weight wire in the tubular steel pole.

Installation
13. Swivel the wheel body (1) in the tubular steel pole so that the clevis (6) fits
into the suspension (3).
14. Insert the hexagon bolt (7) from above through the suspension (3) and
clevis (6) and secure from below with a hexagon nut (8).
15. Adjust the tension wheel assembly in accordance with the project specifica-
tions.
NOTE
The wheel body must be aligned vertically and its teeth must engage with the latching plate 4a).
Check that it is vertical by placing a spirit level against the outer surface of the wheel body.
The bracket (4) has elongated holes that allow for slight corrections in the tension wheel assembly
position.
16. Tighten the bolts between the tubular steel pole and suspension, and
between the suspension and the clevis.
17. Check all screw connections.
6.4 Connecting the tension wheel assembly to weight set and catenary system
WARNING
Twists in the loaded weight wire can cause a structural change of the wire where it winds onto the
wheel body. This can considerably reduce the breaking load of the wire. During installation, please
follow the instructions for avoiding twists in the wire in Section 6.4.1 "Making the connection to the
weight set" on page 33.
6.4.1 Making the connection to the weight set
NOTE
It is recommendable to connect the completely assembled weight set (support bar with weights)
to the weight wire. After the wire has been allowed to unwind, secure the weight set to the weight
guide tube by means of a guide clamp.
Remove any twists or kinks in the wire, for example, through a controlled unwinding of the weight
set by hand. In order to allow the weight set to unwind, it may be necessary to briefly remove the
weight guide tube from the guide clamp.
If a connection procedure is used which differs from the one recommended, it must be ensured
that there are no twists or kinks in the rope. For example, if you connect a support bar to the weight
wire first without weights and then put the weights on the support bar afterwards, you will have to
change the rotating direction of the support bar after every weight you put on the bar. One-sided
winding of the support bar will cause the weight wire to become twisted and create kinks.
The following conditions must be provided by others on site in accordance with

the engineering:
• the weight guide tube is already mounted on the pole and the tension wheel
assembly (depending on type)
• the weight set is complete (support bar with weights)

Installation
• the length of the weight wire from the middle of the tension wheel assembly
to the connecting point on the wedge-type dead-end clamp is determined
according to project specification
• the latching plate is concentrically aligned with the wheel body and firmly
secured and the wheel body is firmly secured on the latching plate.
Proceed as follows:
1. Measure the length of the unrolled weight wire from the middle of the wheel
body to the connecting point on the wedge-type dead-end clamp according
to project specification.
2. Remove the wedge-type dead-end clamp (13a) on the weight wire if the
length of the wire has to be adjusted.
3. When the position of the wedge-type dead-end clamp on the weight wire
corresponds to the specified level of connection, hit the special wedge hard
to drive it into the wedge-type dead-end clamp (13a).
4. Using a suitable lifting device, lift the complete weight set up to the level of
the wedge-type dead-end clamp.
NOTE
When connecting the weight wire to the support bar, make sure that the weight wire is not twisted.
5. Bolt the support bar firmly to the wedge-type dead-end clamp (13a).
6. Secure the bolted connection by inserting a split pin in the pin.
7. Lower the weight set with lifting device.
6.4.2 Making the connection to the catenary system
NOTE
The tension wheel assembly is to be connected to the catenary system in accordance with the
details of each specific project; only an example is described here.
All connecting parts must be suitable for the permissible operating forces in the catenary system
and must be provided on site.
14 16 24a 24 24a 23 24a 25
14 steel wire with connecting fittings 8WL7090-1C 24 catenary/contact wire 1.5 m

16 equalizing pulley and guy clevis 24a dead-end clamp
23 insulator 25 catenary/contact wire (cate-
nary)
Connection to the catenary system (example)

Installation
1. Cut an approx. 1.5-m-long section of catenary wire or contact wire (24)

according to the cross-section of the catenary wire or contact wire to be
tensioned and fit the dead-end clamps (24a) on the ends of the catenary or
contact wire as connecting parts.
2. Insert the thus prepared section of catenary wire/contact wire with the
connecting part into the guy clevis (16).
NOTE
Observe the permissible operating force for catenary or contact wire stringing grips and the ratchet
puller.
3. Fit a catenary or contact wire stringing grip to catenary or contact wire (24).
4. Bearing in mind the maximum length of the ratchet puller, fit a second
stringing grip to the catenary or contact wire (25) to be tensioned.
5. Hook a sling into each contact wire/wire stringing grip.
6. Pull the ratchet puller out to its maximum length and suspend the ratchet
puller in the catenary or contact wire stringing grips.
7. Tension the ratchet puller until the wheel body lifts out of the latching
plate (4) resp. (4a).
8. Adjust the height of the weights according to the individual project specifi-
cations.
9. Move the dead-end clamp on the catenary wire/contact wire to be tensioned
until the connection can be established at the end of the 1.5 m-long piece
of wire/contact wire (24), including insulator (23).
10. Check all connections.
11. Slacken the ratchet puller.
12. Remove the ratchet puller and then the catenary or contact wire stringing
grips and slings.
6.5 Function test and readjustment on the tension wheel assembly

Adjusting of the latching plate
NOTE
The adjustment of the latching plate to the wheel body when in operating position, using variant
8WL5078-1A of the tension wheel assembly as an example, is presented in Figure "Adjusting the
distance between latching plate and wheel body (operating position) on type 8WL5078-1A" on
page 36.
After the tension wheel assembly has been connected to the catenary system
and weight set and after final positioning of the tension wheel assembly in
relation to the track, the distance between the latching plate (4) resp. (4a) and
the wheel body (1) has to be adjusted.

Installation
1. Check the distance between latching plate (4a) and wheel body (1). The
distance between these components must be 48 mm. Readjust the latching
plate if this distance is not as specified.
2. To adjust the distance, loosen the four M12 hexagon bolts (20) to enable the
latching plate (4a) to be moved.
3. Put a distance piece (26) from approx. 3 mm of thickness (e.g. folding rule)
on the latching plate. Push the latching plate to the wheel body (1) and
centre the latching plate to the rim.
4. Tighten the four M12 hexagon bolts (20) to a tightening torque of 56 Nm.
5. Remove the distance piece (26) and check the distance 48 mm.
Detail X
1
3
45
48
26
20 4a
21
22
X
dimensions in mm
1 wheel body
4a latching plate
20 M12x50 hexagon bolt
21 washer
22 M12 hexagon nut
26* distance piece

Adjusting the distance between latching plate and wheel body (operating position) on type
8WL5078-1A

Maintenance
7 Maintenance
WARNING
High electrical voltage can cause death or severe personal injury. Before starting any maintenance
work, deenergize the overhead contact line system or secure the work area and/or the overhead
contact line in accordance with regulations. Follow the five safety rules laid down in EN 50110-1
(see Section 2.4 "Safety requirements" on page 8).
NOTE
As part of a tensioning system in the contact wire system, the tension wheel assembly is subject
to scheduled maintenance which must be organized, carried out and documented by the operator
of the system.
7.1 Inspection
NOTE
Make sure that any defects which detected are rectified.
It is recommended that the tension wheel assembly be inspected two years after
commissioning and preferrably at low temperatures. The system operator must
ensure that the following inspection intervals are observed.
The system operator must inspect the system using the instructions which have
been adapted to the respective operating conditions so that he can fulfil his obli-
gations to ensure its safe operation.
Interval Task
Every two years • Visually inspect the condition of the tension wheel assembly in the
tensioning system and check the mechanical connections (see
Section 7.1.1 "Visual inspection" on page 37)
• Carry out a functional test of the tension wheel assembly (see
Section 7.1.2 "Function test of the tension wheel equipment" on
page 38)
7.1.1 Visual inspection
1. Check whether external influences can hinder movement of the wheel body
(e.g. by branches broken off trees).
2. Check the steel wires for damage (e.g. wire breaks, flattened surfaces,
wear) (see Figure "Flattened surfaces on the wire surface and wire breaks"
on page 38). Please note that wire damage can be covered over with
bitumen.
3. Check the connections to the steel wires.

Maintenance
flattened surfaces wire break
Flattened surfaces on the wire surface and wire breaks
4. Check all mechanical connections (resp. to fixing elements (17) and (18) at
the variants 8WL5078-0A, -0B, -0C, -1A, -1C and -1D to the latching
plate (4) resp. (4a), to the mounting support for the guide tube and addition-
ally at the suspension (3) for the variants 8WL5078-2 and 8WL5078-3.
If no damage to the tension wheel assembly is apparent, carry out a functional
test.
7.1.2 Function test of the tension wheel equipment
1. Move the weights to test the ease of movement of the wheel body and the
wires on the winding faces of the wheel hub and on the circumference of the
wheel body.
2. If the wire drags on the wheel body during movement, or if it runs over the
wound wire, readjust the tension wheel assembly.
3. Check the 48 ± 3 mm distance of the latching plate to the tension wheel
assembly (see Figure "Adjusting the distance between latching plate and
wheel body (operating position) on type 8WL5078-1A" on page 36). If it is
not 48 mm, readjust the latching plate (see Section 6.5 "Function test and
readjustment on the tension wheel assembly" on page 35).
4. Check all connections to the wires.
7.2 Maintenance
Carry out maintenance work according to your evaluation of the inspection
results. The type and scope of maintenance as well as maintenance intervals
are determined by the respective conditions, i.e. climatic conditions, degree of
contamination and the line load.

Maintenance
7.3 Repairs following a fault in the overhead contact line

7.3.1 Repairs following contact wire or catenary breakage
7.3.1.1 Visual inspection of the tension wheel equipment, wires and fixing elements for damage
• Check the steel wires (13) and (14) for external safety-relevant damage.
Damaged steel wires must be replaced.
• Check the wheel rim on the wheel body (1). The wheel rim can be damaged,
especially if high tensioning forces are applied during the latching process.
If you detect such damage, the complete tension wheel assembly and the
weight wire are to be replaced in order to ensure the safety of the system.
The mounting procedure is described in Section 6 "Installation" on page 20.
• Also check the fixing elements and the pole anchor for damage.
If no damage to the tension wheel assembly is apparent, carry out a functional
test.
7.3.1.2 Function test on the tension wheel assembly

1. Check the ease of movement and the movement of the wire on the wheel
hub and on the circumference of the wheel body by moving the weight set.
Readjust the tension wheel assembly if the wire drags on the wheel body
during movement or if the wire runs over the wound-on wire at an angle.
3. Check the 48 ± 3 mm distance between the latching plate and the tension
wheel assembly (see Figure "Adjusting the distance between latching plate
and wheel body (operating position) on type 8WL5078-1A" on page 36). If
this distance has not been adhered to, readjust the latching plate (see
Section 6.5 "Function test and readjustment on the tension wheel
assembly" on page 35).
7.3.2 Repair following short-circuit with current flow through the tension wheel equipment
ATTENTION
The tensioning equipment can be damaged if a short-circuit occurs with flow of current through
the tensioning equipment. For safety reasons, a visual inspection must always be carried out after
a short-circuit with flow of current through the tensioning equipment . Failure to comply can result
in death, serious injury or considerable damage to property.

Maintenance
7.3.2.1 Visual inspection of the tension wheel equipment, wires and fixing elements for damage
NOTE
After a short-circuit with flow of current through the tensioning equipment, the steel wire (14)
between the tension wheel assembly and the catenary system must always be replaced.
Any damaged components are to be replaced before a functional test is carried out!
For instructions on how to mount a new tension wheel assembly and how to
wind wire onto the wheel body, please read Section 6 "Installation" on page 20.
If no damage to the tension wheel assembly is apparent or if damaged parts
have been replaced, carry out a functional test.
7.3.2.2 Function test on the tension wheel assembly

1. Move the weights to test the ease of movement of the wheel body and the
wires on the winding faces of the wheel hub and on the circumference of the
wheel body.
3. Check the distance of the latching plate to the tension wheel assembly (see
Figure "Adjusting the distance between latching plate and wheel body
(operating position) on type 8WL5078-1A" on page 36). If it is not
48 ± 3 mm, readjust the latching plate (see Section 6.5 "Function test and
readjustment on the tension wheel assembly" on page 35).

Disassembly
8 Disassembly
DANGER
Danger to life due to high electrical voltage in the overhead contact line system and due to the
mechanical tensioning forces in the tensioning equipment. Please observe the generally appli-
cable and legally binding safety regulations. Please follow the 5 safety rules set out in Section 2.4
"Safety requirements" on page 8.
8.1 Disassembly procedures

1. Secure the contact wire or catenary wire to be tensioned in the tensioning
equipment by fitting catenary or contact wire stringing grips and slings.
2. Attach a ratchet puller.
3. Use the ratchet puller to take the strain off the contact or catenary wire until
the wheel body rests on the impact plate. Secure the wheel body in this
position.
4. Fasten the weight set to a suitable lifting device. Lift the weights and undo
the connection between the weight set and the weight wire.
5. Detach the wire connecting the tension wheel assembly and the contact
wire or catenary wire.
6. Remove on the variants 8WL5078-0A, -0B, -0C, -1A, -1C and -1D the
screw-type connection between the swing lever (2) and the suspension (3).
7. Remove on the variants 8WL5078-2 and 8WL5078-3 the screw-type
connection between the tubular steel pole (5) and suspension (3).
8. Fasten a suitable lifting device to the wheel body, lift the wheel body away
from the latching plate (4) resp. (4a) and place it down on a firm surface.
9. Remove on the variants 8WL5078-0A, -0B, -0C, -1A, -1C and -1D the
screw-type connection between the suspension and the fixing
elements (17), (18) and (19) and then remove the suspension.
8.2 Recycling and disposal

The components of the tension wheel assembly have been made largely from
materials that canbe recycled or disposed without harming the environment.
Dismantle the tension wheel assembly into its component parts and separate
them according tomaterial.
A prerequisite for the disposal is that the units are in a condition corresponding
to correct and proper usage. Unit parts which cannot be recycled must be
correctly disposed of. The applicable legal requirements must be observed.
We can provide help with disposal. In this respect, please contact your local
Siemens company.

Technical data
9 Technical data
9.1 Order numbers

Variant Order No.
Tension wheel assembly with mounting support 8WL5078-0A
for guide tube up to Ø36 mm
Tension wheel assembly with mounting support 8WL5078-0B
for guide tube up to Ø43.5 mm
Tension wheel assembly without mounting support 8WL5078-0C
Tension wheel assembly with mounting support 8WL5078-1A
for guide tube up to Ø36 mm
Tension wheel assembly on structures 8WL5078-1C
Tension wheel assembly on structures (stainless steel) 8WL5078-1D
Tension wheel assembly for tubular steel pole (reduction ratio 1:3) 8WL5078-2
Tension wheel assembly for tubular steel pole (reduction ratio 1:1.5) 8WL5078-3
9.2 Mechanical and electrical data

Component Value
Ambient temperature [°C] -40 to +48
Efficiency ≥ 0.97
Mechanical advantage reduction ratio
- 8WL5078-0A/-0B/-0C/-1A/-1C/-1D/-2 1:3
- 8WL5078-3 1:1.5
Maximum permissible length variation of contact and [m]
catenary wires
- 8WL5078-0A/-0B/-0C/-1A/-1C/-1D/-2 1.5
- 8WL5078-3 2.3
Perm. operating load [kN] 24
Min. failing load [kN] 72
Weight [kg]
- 8WL5078-0A/-0B 28.5
- 8WL5078-0C 28.0
- 8WL5078-1A 30.5
- 8WL5078-1C/-1D 30.0
- 8WL5078-2 31.5
- 8WL5078-3 33.5

Technical data
9.3 Material
Component Material
Wheel body ctAl (cast aluminium alloy)
Swing lever
- at 8WL5078-0A/-0B/-0C/-1A/-1C/-2/-3 htgSt (steel, hot-dip galvanized)
- at 8WL5078-1D stlSt (stainless steel)
Suspension
Bracket
Latching plate AlMgSi (aluminium wrought alloy)
Bracket for guide tube (strap and angle) htgSt (steel, hot-dip galvanized)
Safety hoop htgSt (steel, hot-dip galvanized)
Screws, nuts, washers stlSt (stainless steel)
9.4 Accessories
Component Order No.
Steel cable 50 mm2 (d = 9.5 mm, specify length when ordering) 8WL7090-0
Steel cable 26 mm2 (d = 7 mm, 7.5 m long) 8WL7090-1C
Steel cable 26 mm2 (d = 7 mm, 9.5 m long) 8WL7090-1G

One-hole wedge (mlCl) 8WL1201-0
Two pin clevis link 19 (htgSt) 8WL1018-0
Equalizing pulley (mlCl) with straps (htgSt) 8WL5160-0
Pulley (mlCl) 8WL2137-4
Guy clevis (mlCl) 8WL5167-4
Wedge-type dead-end clamp (mlCl) 8WL1180-7
Special wedge 50 (mlCl) 8WL1202-3
Adjusting strap for tension wheel assembly, symmetrical (htgSt) 8WL5006-1A
Adjusting strap for tension wheel assembly, asymmetrical (htgSt) 8WL5006-2A
Adjusting strap for tension wheel assembly in tunnel (htgSt) 8WL5006-3A
9.5 Accessories (optional)

Component Order No.
Sensor for Sicat CMS on the tension wheel assembly 8WL5067-0

Siemens AG
Industry Sector
Mobility Division
Mozartstraße33b
91052 Erlangen
Germany
electrification
Sicat 8WL5078
A6Z08111121403 / Status: 2011-05-09

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EJECUCION DE LAS OBRAS CIVILES Y

ELECTROMECANICAS DEL SISTEMA ELECTRICO DE

LINEA 1 : TRAMO VILLA EL SALVADOR- AVENIDA GRAU

01 07-NOV-11 APROBADO PARA CONSTRUCCIÓN SIE MPE SPD

0A 10-AGO-11 EMITIDO PARA REVISIÓN SIE MPE SPD

Identificación de la documentación: Estado :

Manual de Operación y Mantenimiento

Aprobado con comentarios Cód. 2 1/50

Rev. N° Estado Descripción de la Revisión

0A EPR EMITIDO PARA REVISIÓN

01 APC APROBADO PARA CONSTRUCCIÓN

1. ALCANCES Y PROPOSITO ...................................................................................................................... 5

5. REGLAS DE SEGURIDAD GENERALES ................................................................................................. 6

6. DESCRIPCION GENERAL ........................................................................................................................ 8

7. HILOS DE CONTACTO Y CABLES ......................................................................................................11

8. BRAZOS (MENSULAS) ...........................................................................................................................41

8.1 LUGAR DE MONTAJE: .........................................................................................................................41

ANEXO A: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE LOS SECCIONADORES ........................48

ANEXO B: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE AISLADORES DE SECCIÓN .................49

ANEXO C: MANUAL DE OPERACIÓN Y MANTENIMIENTO DE POLEAS ..................................................50

El presente manual describe los procedimientos de operación y mantenimiento necesarios para el

No se pretende reemplazar o influenciar las normas nacionales, regionales o internas vigentes.

El sentido del mantenimiento es evitar lo más posible las fallas en la instalación.

CTEL-SIE-ELT-CLP-PRG-52738 Plan de Capacitación - Sistema de Catenarias

Término Description (English) Descripción (Español)

5. REGLAS DE SEGURIDAD GENERALES

Las presentes reglas de seguridad no anulan o modifican las normas vigentes.

5.1 EL MANEJO DEL TREN

5.2 TENSIÓN ELÉCTRICA

5.3 PUESTA A TIERRA

Figura 01. Barra de Puesta a Tierra

5.4 TRABAJO EN ALTURAS

6.1 FUNCIÓN DE LA CATENARIA DENTRO DEL SISTEMA ELÉCTRICO

Figura 02. La Catenaria como parte del Circuito de Corriente

El aislamiento se ha diseñado para la tensión nominal de 1500 V y considerando las condiciones

6.2 DISTRIBUCIÓN DEL SUMINISTRO ELÉCTRICO EN LA CATENARIA

Figura 03. Esquema de Distribución de Vanos de Catenaria Lineas Principales.

Figura 04. Pantografo.

7. HILOS DE CONTACTO Y CABLES

7.1 LUGAR DE MONTAJE

7.2 DESCRIPCIÓN Y DATOS TÉCNICOS

Figura 05. Catenaria

7.2.1 Cable Mensajero.

7.2.2 Hilo de Contacto.

Para su colocación se aprisionan los extremos con un terminal de cable y se aseguran

Las péndolas externas dentro de un vano se sitúan a 5 m, a la derecha e izquierda, del

Figura 06. Péndola para Cable Sustentador Sencillo

Figura 07. Pendola para Cable Sustentador Doble

Distancia : Mástil - péndola Distancia entre mástiles

5.00 16.00 21.00

5.00 11.00 22.00

5.00 11.50 18.00 23.00

5.00 12.00 19.00 24.00

5.00 12.50 20.00 25.00

5.00 13.00 21.00 26.00

5.00 13.50 22.00 27.00

5.00 14.00 23.00 28.00

5.00 14.50 24.00 29.00

5.00 15.00 25.00 30.00

5.00 15.50 26.00 31.00

5.00 16.00 27.00 32.00

5.00 12.67 20.33 28.00 33.00

5.00 13.00 21.00 29.00 33.00