NEW STINGER SYSTEM - · PDF fileThe objective of this document is to provide a general description of the Stinger system and the ... maximum temperature up to 145 ... to slide the

1 INTRODUCTION | Alstom Transport

NEW STINGER SYSTEM


SUMMARY

1. INTRODUCTION ......................................................................................................................................................... 3

2. APPLICATION PURPOSE ............................................................................................................................................ 3

3. PRODUCT DESCRIPTION ........................................................................................................................................... 4

3.1. INSULATED CONDUCTOR RAIL SYSTEM FOR ENERGY SUPPLY ........................................................................ 5

SUPPORT HANGERS .................................................................................................................................. 5 3.1.1.

CONTACT RAILS ......................................................................................................................................... 5 3.1.2.

RIGID JOINT CLAMPS ................................................................................................................................. 6 3.1.3.

FEEDER CLAMPS ....................................................................................................................................... 8 3.1.4.

FIXED POINT HANGERS ............................................................................................................................ 9 3.1.5.

END CAP .................................................................................................................................................... 9 3.1.6.

3.2. CURRENT COLLECTORS ................................................................................................................................... 10

3.3. TROLLEY ON STEEL TRACK RAIL ..................................................................................................................... 12

3.4. ELECTRICAL AND CONTROL PANEL WITH CABLES ......................................................................................... 16

3.5. SOCKET FOR POWER TRANSMISSION TO THE VEHICLE AND RAPID SECURE LINK (ON DEMAND)............. 18

4. TECHNICAL DATA..................................................................................................................................................... 20

5. MAINTENANCE INSTRUCTIONS .............................................................................................................................. 22


1. INTRODUCTION

The objective of this document is to provide a general description of the Stinger system and the relevant insulated conductor rail

system for electrical power supply (installation recommendation).

The following symbols and references are used in this manual to give instructions and warnings (cautions) of particular

importance. These must always be strictly observed!

NOTE:

Refers to special information on how to use the equipment safely and efficiently.

CAUTION:

Warns of general dangers. Danger of injuries and damage to property.

CAUTION:

Warns of danger of electrical shock from live equipment.

The operating instructions must always be kept at an on-site location near the Stinger System where they can be readily accessed.

In addition to the operating instructions, general regulations regarding accident prevention and environmental protection are to be

observed.

Read the following assembly and maintenance instructions before starting the installation of the line.

All personnel working on the conductor system should be correctly trained and authorized to operate on the energy supply system

in compliance with relevant standards, regulations and laws. Furthermore only authorized and qualified maintenance personnel

may work with the stinger system and conductor rail system and all personnel working has to able to recognize and avoid risks

and possible dangers which may occur during operation.

2. APPLICATION PURPOSE

Stinger systems serve as energy supply for rail vehicles as suburban and underground in depot and maintenance area separated

from their main power supply (i.e. third rail or catenary). The power in these areas is supplied by current collector trolleys that can

move on conductor rails fixed close to ceiling. The power received by a special cable over current collector trolleys is acquired to

vehicle by proper sockets. This system is developed from inside applications. For the installation of the conductor rails and other

working condition refer to following chapters.

4 PRODUCT DESCRIPTION | Alstom Transport

3. PRODUCT DESCRIPTION

The system is composed by different items grouped in the following sets:

a) Insulated conductor rail system for energy supply

b) Current collectors

c) trolley on steel track rail

d) Electrical and control panel with cables

e) Socket for power transmission to the vehicle and rapid secure link (on demand)


3.1. INSULATED CONDUCTOR RAIL SYSTEM FOR ENERGY SUPPLY

The insulated conductor rail ALINOX is a solution for the electric feeding of the Stinger system, suitable for load up to 1300 A.

ALINOX is designed and realized in order to offer the best safety guarantees against accidental contact, according to the standard

EN 60529, in particular the protection degree of housing is IP23. The conductor is made of aluminum and stainless steel and all

bolts and nuts are in stainless steel.

The system is available from 400 A up to 1300 A, and it could be used for power and control system. The range for admissible

temperature for standard PVC insulating housing (addition of the ambient and the operating temperature) is -30°C +85°C, for

the power of 900, 1100 and 1300 A is available NORYL insulating housing with maximum temperature up to 145°C.

The insulated conductor rail system will be installed onto the existing support structure. The mechanical correct installation of the

support arm must be checked before the start of conductor rail installation.

SUPPORT HANGERS 3.1.1.

The insulated conductor rail system will be installed onto the existing support structure. The mechanical correct installation of the

support arm must be checked before the start of conductor rail installation. The support hangers have to be fixed to the respective

iron brackets, which have been installed according to Pict. 1 where is shown the attachment to a “I” or “H” profile supporting

beam, using two shaped plates, which position can be adjusted along the brackets, in order to fit it. This is only an example of

installation, the system could be developed according to the requested layout. There are 2 types of support hanger : one for 750 V

in DC and another for upper voltage composed with a fiberglass insulator up to 1500 V ( DC).

Pict.1 (example of composition) Pict.2

The brackets have to be drilled keeping a minimum distance of 70 mm among the phases (when is a required a three phase

system. The standard installation pitch of the brackets is 2 m maximum.

Particular attention has to be paid during the installation of the brackets, fixing them to the wall or to the beam, in order to keep

them as aligned as possible, to guarantee a straight and parallel run of contact rails.

CONTACT RAILS 3.1.2.

The rails are supplied in standard pieces 4 m or 6m long (according to the load); they must be assembled placing them side by side

horizontally (at a minimum distance of 70 mm among them), hooking them on one side in the support hanger (pict 2) and then

turning them in the support hanger until they are also attached to the other side. Another method of assembly consists on

inserting the bar into the front of the support hanger. Then you have to slide the rail along, until it joins to the adjacent conductor

rail.


Important Remark: the distance between each joint of one rail to the next, and the closest support hanger must always be 300

mm. In this way, being the support hangers mounted with pitch 2 m and being the rail 4 m long, the joints between two sections

will be always 300 mm away respect to the support hangers.

Pict.2

RIGID JOINT CLAMPS 3.1.3.

Pict.3

Before mounting the joint clamp on the line do the following operations:

• Brush with a metal (stainless steel) brush the contact surfaces of the joint clamp and contact rail.

• Apply a thin layer of white vaseline on the front surface of the contact rail or joint clamp

The joint clamps are supplied in polythene bags containing the electric joint clamp, the insulating joint cover box.

The electrical connecting clamp is composed of one stainless steel plate and an aluminium component assembled with 4 M10

screws, nuts, complete with washers (pict 3).

Fit the clamp to the rail, space lightly the extremities of the rails and insert the upper part of the conductor between stainless steel

plate and the aluminium component; move the other contact rail inserting the extremity as mentioned before and then tighten the

4 nuts taking care to centre the joint clamp (recommended torque 20 Nm). During the assembling phase make sure that the lower

parts of the conductors are perfectly aligned and not twisted each other as shown in pict. 4 in order to avoid the outcome of the

contact shoe due to the stumbling or bouncing over the joint passage.

In case this happens, you have to align the extremities, with the help of two pliers positioned on the extremities and rotating them,

one in the opposite sense of the other.


Pict.4

Remarks: in the unlikely case of presence of burrs near the extremities of the conductor, you must remove them before mounting

the terminal, in order to avoid any irregular wear of the contact shoes.

Then mount the two click half boxes that cover the joints as shown in the following photos.

1 2

3 4

NO


FEEDER CLAMPS 3.1.4.

Pict.5

The feeder clamp must be installed where indicated in the installation diagram in substitution of a Joint Clamp.

Before mounting the feeder clamp on the line do the following operations:

Brush with a metal (stainless steel) brush the contact surfaces of the feeder clamp and contact rail.

Apply a thin layer of white Vaseline on the front surface of the contact rail or feeder clamp.

The feeder clamps are supplied in a polythene bag containing the electric feeder clamp, composed by a feeding plate, rigid joint

clamp and related plate), two half-boxes with the relevant coupling self-tapping screws and four conical cable glands.

The feeder clamps are realized with two components that have 4 holes for M10 screws in the lower part to be fixed to the

conductor rail and 4 threaded holes M12 in the centre to link the feeder terminal.

To assembly the clamp to the rail, slightly separate the extremities of the rails and insert the upper part of the conductor between

the stainless steel plate and the aluminium component (pict. 5); move the other contact rail inserting the extremity as mentioned

before and then tighten the 4 nuts taking care to centre the joint clamp. (Recommended torque 20 Nm).

Cut the cone of the cable gland so that its diameter is slightly lower than the outer diameter of the cable; insert the extremity of

the cable into the cable gland, connect the terminal connector at the extremity of the cable and then fix the terminal connector to

the feeder clamp with the M12 screw (Recommended torque 40 Nm).

Remove from one side, through a “cutter”, the round part of cable wall of the two half-boxes, on the side where the cable will be

inserted; fit the cable together with cable gland between the two insulating half-boxes and then fix them one to the other

through five self-threading screws .


FIXED POINT HANGERS 3.1.5.

Pict.6

They are used to determine a fixed point on the line. They must be mounted between two expansion joints or between an

expansion joint and the extremity of the line.

In case of lines for which expansion joints are not necessary, it will be enough to install one fixed point hanger per phase in the

middle of the line. The fixed point hangers are similar to the support hangers, but they are equipped with a couple of half-joint

(Pict.6).

END CAP 3.1.6.

The end caps are threaded on the contact rail at the extremity of the line.


3.2. CURRENT COLLECTORS

The current collector is fixed to the brackets, realized with steel profiles 60x60x6. (pict.7). When you install the brackets on the

IPE, you have to respect the distance of 220 mm between the support surface of the base of the current collector and the sliding

surface of the contact shoe.

Besides you have to do all the possible so that the axis of the fixing hole of the current collector is aligned with the fixing one of

the support hanger of the overhanging line. (pict. 8). The contact shoe is then inserted into the two lower nibs of the insulated

profile of the contact rail, which act as a guide.

The derivation cable from the current collector (excluded from our supply, maximum section 25 mmq) is connected directly to

the shoe, inserting it into one of the two lateral holes you find on the insulating cover containing the shoe. The insulating cap,

already mounted, closes the other hole.

REMARKS: the cable must have an abundant loop and be fixed to the lower arm of the current collector, by means of a hose

clamp, to avoid limitations of the articulations of the contact shoe and consequently possible bad contacts on the conductor (pict.

9).

Pict.7


Pict.8

Pict.9


3.3. TROLLEY ON STEEL TRACK RAIL

The system is supported by means trolley that runs upon the structural beam. The operators is able to pull up the system by means

rope in order to reach easily the exact connection point with the vehicle in maintenance area.

The leading trolley is realized in order to ensure the maximum handling capacity motion on steel track rail without incurring in such

problems of wear of the wheels having frequent maintenance activities as consequence.

Warning: if the system is equipped with rapid secure link, is forbidden to fix the pull rope to the vehicle to be driven during train

movement within maintenance area. In this way the rapid secure link is by passed!

13 | Alstom Transport

Main characteristics:

Weight : very light system thanks to usage of light materials for construction

Anti-jump wheel : to increase the stability of the trolley during the motion on the beam

Dumper : one on each side of a trolley to absorb the impact between two adjacent Stinger System

14 Main characteristics: | Alstom Transport

Contrast wheels : to increase the lateral stability during the motion along the beam

Fast Installation : simplicity of installation thanks to the marks on the transverse beam


Weld less : no welding to reduce the weight, increase the resistance and decrease the cost

Expandability : possibility to add Signal Rails or Power Rails even on Stinger System already installed


3.4. ELECTRICAL AND CONTROL PANEL WITH CABLES

The product provides the relevant command and control of Stinger System in a selective mode. Each Stinger belonging to the

same feeding line can be switched “ON” or switched "OFF" depending of operating needs.

PENDANT REMOTE CONTROL DESCRIPTION:

The operators using the pendant remote control above is able to activate or deactivate such system according to the following

state condition:

1. Key security switch on remote control : ON

2. Rapid secure link connected (if equipped)

3. Jupiter plug connected to the vehicle

4. Green Light on control panel switch ON automatically

If all the above states are satisfied, the system is in “Stand-by” state and the operator can push the Green button on

remote control to switch “ON” the System.


** Is enough just one condition didn't satisfied than the state above mentioned to get “Inhibit state” of the

system

Just after green button pushed the system goes in “ Working on“ state:

5. Green Light on control panel switch OFF automatically

6. Red light on remote control and control panel switch ON automatically (redundant light signalization)

7. The buzzer is activated automatically for 5 seconds then is stop.

By the “ Working on“ state the system can returns in the state:

1. “Stand by”

1a:If the operator push the red button on remote control (Operating condition)

2. “Inhibit “

2a. if the operator switch off the key on remote control (Operating condition)

2b: if the rapid secure link is disconnecting (Emergency condition)

2c: if the Jupiter plug is disconnected from the vehicle (working condition not foresee)

Especially relating to the case 2b, the system is able to actuate a protection in order to interrupt the voltage supply just one instant

after the mechanical plugs disconnecting avoiding electric arc and potential injury to the operators.

We precise that the case 2c is not a contemplated case over the normal activities of the Operators under High voltage presence.

The system even in this case actuates the interruption of Voltage supply.

take note that all the protections actuated by the system are simply a primary protection to mitigate all the potential risk

of device damaging or injury prevention, Under no circumstances, those protections shall be considered exhaustive to avoid

damages to the things or to the worker especially if the workers doesn’t respect the right working instruction.


To restore “Inhibit state” from Emergency condition cases 2b-2c, the Operator shall:

3. Turn the Key switch on remote control in position “OFF”

4. Push the button Red “stop” on remote control

5. The presence of green light on panel control “ ON”

6. The absence of red light on Panel control and remote control “ OFF”

7. Re connect the rapid secure link or Jupiter plug

8.

Please refers to the table here after for component localization and summary working operation:

3.5. SOCKET FOR POWER TRANSMISSION TO THE VEHICLE AND RAPID SECURE LINK (ON DEMAND)

The socket or plug interface with the vehicle is typically defined by Client or Train integrator who define the type and

relevant characteristics.

This plug permits the distribution of power supply directly to the vehicle interlocked into a dedicated socket installed from

Vehicle side.

Please refers to the chapter “Technical data“ hereby about plug characteristics for project.

RAPID SECURE LINK (If equipeed)

location function

line Contactor

vehicle plug interface shunt of jupiter plug metro side , close the negative loop when the movable plug is inserted

remote control

remote control

remote control

remote control + control panel

green lamp

p lug interface

type

key b lock

button ON

button OFF

red lamp

control power supp ly

rap id secure link

jup iter/shunt

regolab le buzzer

vehicle plug interface

control panel

HV presence, regolable buzzer intermitted sound for 5 seconds, buzzer on when the KL1 is powered

power line contactor drived by the logical condition,

control unit low voltage power line 48Vdc

plug Metro interface

control panel

control panel

control panel

frangible link plug

HV absence, green light visible on cabinet, when the KL1 is open and p1 not pushed -

without key inserted is not possible to close negative loop circuit of power control -system disabled

button pushed in ON - system enable = Key inserted and in position = 1;

button pushed in OFF -System interruption - all position of the key

HV presence, red light visible directly on remote control by the operator, light on when the KL1 is powered

pilot pin of frangible, close the negative loop when the frangible plug is completly inserted


The Stinger System is equipped with a secure rapid link for the case of an emergency. If the rail vehicle moves out of the

maintenance area, the connection cable is separated at secure link (1), before a high traction force causes a major damage

on the Stinger System. If traction force exceeds a certain limit please refer to the Technical data chapter, the secure rapid

link disconnects at first the control circuit and then, after a short time, the energy line. This measure prevents building up

an electric arc, which can injure personnel. Then both Stinger Systems in the road will be switched OFF.

Please refers to the chapter 3.4 to restore “Inhibit state”

** The Operators mustn’t removed, during the normal maintenance activities under High Voltage the rapid secure link or

Jupiter plug !

1

20 TECHNICAL DATA | Alstom Transport

4. TECHNICAL DATA

Conductor rail

Power conductor rail: Type Alinox (Al – stainless steel)

Number of conductors: Possibility of different layout

Voltage: 750 VDC � 1500 Vdc

Continuous rating: 500 A range 400 A�1300 A

*Control conductor rail: Type Alinox (Al – stainless steel)

Number of conductors: Possibility of different layout

*Voltage: 24 VDC � 110 Vdc ; 48Vac� 120 Vac 50hz

Continuous rating: up to 5,2 A

Insulating material PVC or NORYL -CEI EN60439-2

Protection: IP23

Direct contact protection EN60529

*The system can produce itself the Voltage to supply Control unit directly from the Power conductor line

Collector trolley (including control panel)

Collector trolley: hot dip galvanized steel

Number of trolleys: 1

Current collectors: 2x 200 A (double collector) for power

Number of current collectors: 1 per trolley, possibility of different lay-out

Control collectors: 2x 100 A (double collector) for control

Number of current collectors: 1 per trolley possibility of different lay-out

Voltage: 750 VDC

Continuous rating: 300 A per trolley

Indication lights: Green – Red , Yellow not used, Buzzer (timing adjustable)

Weight Control Panel including trolley

(Without cables): 30kg

Electrical Diagram Cariboni Dwg xxxxx

Towing speed: 1.1 m/s (max.)

Pull force: ≤ 25N ? (EHS compliant)

Protection: IP 54

Normative: please refers to the electrical diagram of the system

Control pendant

Pushbuttons: “Start” – Green; “Stop” – Red, security Key switch

Indicator lamps: “Red” Voltage presence

Protection: IP65

21 MAINTENANCE INSTRUCTIONS | Alstom Transport

Connection cable

Cable type: Ultra flexible unipolar cable 120mm^2

Insulation material: class 5

Number of strands and cross section energy: 4 x 25 mm²

Number of strands and cross section control: 2 x 16 mm²

Diameter: 23,5 mm

Cable length: 8 meter

Rapid secure Link

Type: Mechanical disconnecting including early Voltage break Connectors

Release traction force: 35-40N

Material shear rod: xx

Length of buffer cable loop: xx

Protection: IP55

Vehicle connector

Type: FICHE PAT 2621 Souriau (depending of Customer/Train requirement)

Park receptacle

Type: RECR2621 –Souriau (depending of Customer/Train requirement)

Environmental conditions

Temperature: +3°C to +48°C

Humidity: 59% to 90%

22 MAINTENANCE INSTRUCTIONS | Alstom Transport

5. MAINTENANCE INSTRUCTIONS a) Insulated conductor rail system for energy supply

b) Current collectors

Remember to check the recommended torque, reported in this table:

Screw/nut Torque Nm

M6 8

M8 12

M10 20

M12 40

In order to verify that there are no mistakes in connecting the cables of the power terminals we suggest to check the

sequence of the phases. After the installation it is advisable to check the insulation resistance, in order to verify that

there aren’t components damaged during assembly.

MAINTENANCE PROGRAM TO GUARANTEE THE BEST WORKING CONDITIONS

WHAT WHEN HOW TO DO

CHECKING OF THE WEAR OF THE CONTACT SHOES

QUARTERLY

SEE POINT "A"

CHECKING OF THE PRESSURE OF THE CONTACT SHOE SEE POINT "B"

CLEANING OF THE SECTIONALIZING JOINTS SEE POINT "C"

CHECKING IF THE RAIL EASILY SLIDES INTO THE SUPPORT

HANGERS

HALF YEARLY

SEE POINT "D"

CHECKING OF THE TIGHTENING OF THE FIXING SCREWS OF

THE CURRENT COLLECTOR TO THE BRACKET SEE POINT "E"

CHECKING OF THE OPENING OF THE EXPANSION JOINT SEE POINT "F"

TEST OF THE SLIDING OF THE EXPANSION JOINTS SEE POINT "G"

CHECKING OF THE TIGHTENING OF THE JOINT AND FEEDER

CLAMPS YEARLY

SEE POINT "E"

CHECKING OF THE TIGHTENING OF THE FIXING SCREWS OF

THE SUPPORT HANGERS SEE POINT "E"

A. CONTACT SHOES

The contact shoes have to be replaced when the wear has reached the replacing line engraved on one side of the

contact shoe. The replacement is made unscrewing the two screws, which tighten the two parts of the insulating

shoe-holder , unscrewing the screw, which fixes the cable to the shoe; then remove the worn-out contact shoe and

insert the new one as shown in the previous point.

B. SPRINGS OF THE CURRENT COLLECTORS

The springs have to be replaced when the pressure in working conditions is lower than 2 Kg.

C. PERIODIC CLEANING OF THE LINE

Remove eventual deposits of dust, grease or other, that may be present on the insulating housing of the rail, the

support hangers or the current collectors, which could reduce the insulation distances.

D. PERIODIC CLEANING OF THE SLIDING AREAS

Remove eventual deposits of dust, grease or other, that may be present on the insulating housing of the rail, which

could prevent the free sliding of the rail into the support hangers during the expansion; the same for the contact shoe

sliding area.

E. TIGHTENING OF THE SCREWS

Check the tightening of the various screws by a dynamometric wrench rated to the suggested values (M10 20Nm,

M12 40 Nm…)

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NEW STINGER SYSTEM - · PDF fileThe objective of this document is to provide a general description of the Stinger system and the ... maximum temperature up to 145 ... to slide the