Instruction manual DT2202/102 rev C Section insulator ...

Instruction manual DT2202/102 rev C Section insulator JG2202/102

GALLAND S.A.S 255, ZI de l’illot FR-33240 LA LANDE DE FRONSAC

Tél. +335.57.94.07.20 Fax. +335.57.94.07.11 www.galland-sas.com [email protected]

http://www.galland-sas.com/

mailto:[email protected]

Instruction manual

DT2202/102

GALLAND S.A.S 255, ZI de l’illot FR-33240 LA LANDE DE FRONSAC Tél. +335.57.94.07.20 Fax. +335.57.94.07.11 www.galland-sas.com [email protected]

Section insulator Reference : DT2202/102

Page : 2 to 25 Revision : C

Date : 02/05/2018

Contents

I. Generality ...................................................................................................... 3

1. Concerned products ................................................................................... 3

2. Upon receipt ............................................................................................. 3

3. Crossing ................................................................................................... 4

4. Condition of use ........................................................................................ 4

5. Section insulator JG2202/102 ind E presentation ........................................... 5

6. Tools required ........................................................................................... 5

7. Tools required for maintenance ................................................................... 7

II. Setting up and adjusting on catenary system ................................................... 8

1. Stagger of contact wire .............................................................................. 8

2. Preliminary operations ............................................................................... 8

3. Installation of anchoring clamps on contact wire ........................................... 9

4. Use of the setting tool JG3605 ...................................................................10

5. Cut of the contact wire ..............................................................................12

6. Installation of the section insulator JG2202/102 ind E ...................................13

7. Use of the adjusting gauge JG2233 ind E ....................................................15

8. Adjusting of transition between contact wire and runners ..............................16

9. Adjusting of parallelism of section insulator with regard to track level .............18

III. Final checking .............................................................................................24

IV. Maintenance et inspection ............................................................................25



Instruction manual

DT2202/102




Date : 02/05/2018

I. Generality

1. Concerned products

Section insulators concerned by this setting up and maintenance manual

DT2202/102 revision B are section insulators dedicated for the electrical segmentation in

25000 V single phase 50 Hz on main line, such as the section insulators JG2202 :

- JG2202/102 index E : Section insulator with suspensions droppers for contact wire

BC 107 mm² or BC 120 mm² according to EN 50149.

N.B. For other contact wire dimensions or clamping groove shapes please contact

GALLAND for any further details.

Stainless steel runners are adjusted individually, in

the same plane to avoid final adjustments on

overhead catenary

2. Upon receipt

The section insulator is delivered in a cardboard box.

The section insulator must be imperatively preserved in its packing until the

setting up.

Upon receipt, the section insulator JG2202 is pre-assembled. It consists of several

elements seen on Image 1 :

- 1 section insulator body with its runners non adjusted,

- 2 anchoring clamps,

- 6 spacer claws,

- 4 suspension braces,

- 4 turnbuckles,

- 4 thimbles,

- 4 sleeves,

- 4 half-suspensions in stainless steel cable Ø5.



Instruction manual

DT2202/102




Date : 02/05/2018

Image 1 : Components of section insulator at receipt

3. Crossing

This section insulator provides electrical insulation between two elementary sections of

the traction overhead equipment. Crossing is continuous for current collection of electric

rolling stock without any rupture of the plane of contact catenary / pantograph.

This section insulator can be crossed, in a preferential direction of circulation, up to a

speed of 160 km/h.

It is not recommended powering through section insulator when train

negotiates it.

4. Condition of use

- This section insulator is designed to be used with a supply voltage of 25000 V.

- It is to be used in installations when the realization of common air-gap overlap

span is not possible.

- To replace special sectioning.

- It has an air gap of 220 mm.

For neutral section assembly, used to avoid mixing

currents from two subsequent substations, it is recommended to install Galland's Neutral Section.

Please contact Galland for any further details

Spacer claws

Section insulator body

Thimbles

Turnbuckles

Half-suspensions Anchoring clamps

Sleeves

Suspension braces



Instruction manual

DT2202/102




Date : 02/05/2018

5. Section insulator JG2202/102 ind E presentation

The Image 2 below illustrates succinctly the different parts of the section insulator

JG2202.

Image 2 : Section insulator JG2202/102 ind E with suspensions droppers

6. Tools required

- A setting tool JG3605 (Image 3). However, a conventional equipment as a

stretcher can be used but this one will form kinks on the contact wire, detrimental

to a good crossing.

This setting tool JG3605 associated with the manual pump

N73003 enable a quick and easy setting up of section insulator

avoiding kinks on contact wire.

Image 3 : Setting tool JG3605

Stiffener and spacer claws

Suspension braces

Stainless steel runner Blowing horn

Anchoring head

Hydraulic jack

Contact wire guide

Fix die with stop pin

Contact wire guide

Movable die with stop pin

Turnbuckles and suspension droppers

Insulated rod

Adjusting screw



Instruction manual

DT2202/102




Date : 02/05/2018

- A manual hydraulic pump N73003 with a high pressure hose of 3 meter long

equipped with a half valve (Image 4).

This manual pump N73003 associated with the setting tool

JG3605 makes it possible to resume mechanical tension of the

contact wire in a secure and fast way.

Image 4 : Manual hydraulic pump N73003

- A stagger, height and cant measurement device as the one presented below on

Image 5 :

Image 5 : Stagger, height and cant measurement device

Half-valve

Hose

Pump

Stagger, height and cant measurement

device

Track



Instruction manual

DT2202/102




Date : 02/05/2018

- A torque wrench as (Image 6) :

Image 6 : Torque wrench with spanner sockets of 16 and 17 mm

7. Tools required for maintenance

- An adjusting gauge JG2233 ind E (Image 7).

This adjusting gauge JG2233 has been design to adjust

precisely the position of the stainless steel runners with

regards to contact wire for a best crossing.

Image 7 : Adjusting gauge JG2233 ind E

Reference plane for stainless steel

runners and contact wire

Spanner socket

Locking axle

Reference plane for stainless steel runners and contact wire

Section insulator handle of fixation



Instruction manual

DT2202/102




Date : 02/05/2018

II. Setting up and adjusting on catenary system

1. Stagger of contact wire

Position the section insulator, in alignment or in curve, in order to have no stagger of

contact wire at its plumb. A tolerance of ± 50 mm is authorized compared with the axis

of the track (Image 8).

Image 8 : Maximal stagger of contact wire: ± 50 mm

N.B. To measure the stagger use a stagger, height and cant measurement device as the

one presented on Image 5.

If a messenger insulator is already present in the span, position the section insulator

centered compared with this one. Otherwise, install first the messenger insulator at the

location where the section insulator is to be installed and follow the next instructions.

Warning

The section insulator must be centered compared to the messenger insulator

2. Preliminary operations

Before installing the section insulator JG2202, it is necessary to remove the runners and

unscrew to the maximum the two adjusting H M12 screws of the anchoring heads of the

insulator. The bottom of the screws should not be longer than the anchoring heads

anymore (Image 9).

Center line



Instruction manual

DT2202/102




Date : 02/05/2018

Image 9 : Remove the runners and screw off adjusting screw

3. Installation of anchoring clamps on contact wire

Prepare two stiffeners of minimum 800 mm long (straight pieces of contact wire). Then,

on the contact wire fit the two anchoring clamps spaced out by a distance between

centers of 852 mm, according to Image 10.

Tighten definitely the anchoring clamps:

- first, screw in H M10 screws with a torque wrench to 5 daN.m

- second, tighten H M10 nuts to 2 daN.m.

Image 10 : Position anchoring clamps on contact wire

Warning

Half-anchoring clamps are threaded therefore an excessive tighten of the nuts

may unscrew the clamps

Torque: - H M10 screws : 5 daN.m - H M10 nuts : 2 daN.m

Anchoring clamp

Runners and blowing horns with screw and nuts HFR



Instruction manual

DT2202/102




Date : 02/05/2018

Place spacer claws as well as suspension braces temporarily tightened by hand according

to the dimensions noticed on Image 11.

Image 11 : Set up spacer claws and suspension fittings

4. Use of the setting tool JG3605

Remove stop pins from movable and fix dies, and present the setting tool under the

contact wire. The contact wire should be positioned in the guides provided for this

purpose (Image 12).

Engage both stop pins behind the anchoring clamps watching that pin chains do not

interfere the installation of the section insulator.

Image 12 : Use of the setting tool

Torque: - do not tighten spacer claws in order that stiffeners and contact wires can adjust themselves during the final setting

Stop pins

Spacer claws

Suspension braces



Instruction manual

DT2202/102




Date : 02/05/2018

Pump until both stop pins get into contact with anchoring clamps checking out they are

well inserted in notch of movable and fix dies as shown in Image 13. Then, resume the

mechanical tension of the contact wire by acting slightly on the pump.

Then move closer the both anchoring clamps of one or two millimeters maximum.

Image 13 : Recover the mechanical tension of contact wire

Warning

An excessive pumping of the jack provokes the compression of the contact wire and

makes cutting difficult

Notch

Anchoring clamp



Instruction manual

DT2202/102




Date : 02/05/2018

5. Cut of the contact wire

Cut the contact wire, in the middle, between the two anchoring clamps (Image 14).

Image 14 : Cut the contact wire

Bend both ends of the contact wire of an angle of about 45°. This essential operation

allows a good crossing of the pantograph without shocks because it creates a slight bend

at the ends of the contact wire (Image 15).

Image 15 : Bend the contact wire



Instruction manual

DT2202/102




Date : 02/05/2018

Then, cut the contact wire close to the edge of the anchoring clamps (Image 16).

Image 16 : Detail of the wire cutting

6. Installation of the section insulator JG2202/102 ind E

Operate again on the hydraulic jack until axes of the anchoring clamps match the slotted

holes of the anchoring heads. Now, axes must be distant from approximately 827 mm.

(Image 17).

Present the section insulator above the contact wire and put it on the anchoring clamps

(as the section insulator is not symmetric, there is a preferential orientation).

Check that anchoring clamps are well positioned in the clevis of the anchoring head.

Image 17 : Set up the section insulator



Instruction manual

DT2202/102




Date : 02/05/2018

Once, the section insulator is in right position, remove the setting tool. For this, by acting

manually on the pump releases as slow as possible hydraulic pressure while making

sure the axles of anchoring clamps are well in the clevis, Image 18.

Image 18 : Check anchoring of section insulator

Warning

Make sure that anchoring clamps are well positioned in the clevis of the anchoring heads

As soon as stop pins rotate on themselves freely by hand, the section insulator is in

position (Image 19). Put off stop pins in order to remove the setting tool.

Visual control

Visual control



Instruction manual

DT2202/102




Date : 02/05/2018

Image 19 : Resume mechanical tension of the setting tool by section insulator

After that, install the runners with the blowing horns and tighten them temporarily by

hand

7. Use of the adjusting gauge JG2233 ind E

Move the adjusting gauge under the section insulator body making sure that the locking

axle is removed and the handles of fixation are untightened (Image 21).

Image 21 : Install the adjusting gauge

Image 20 : Remontage des patins et raidisseurs



Instruction manual

DT2202/102




Date : 02/05/2018

Block adjusting gauge using the locking axle and the handles of fixation as on Image 22.

8. Adjusting of transition between contact wire and runners

To ensure a good crossing of the pantograph under the section insulator, the transition

between the contact wire and stainless steel runners should be imperceptible. Tighten

H M12 adjusting screws of the anchor heads to be in contact with stiffeners. Then

continue to act on the screws to make contact wires tangent to the leading edge of the

adjusting gauge.

Image 22 : Fix the adjusting gauge on the section insulator

Image 23 : Adjust the adjusting screws



Instruction manual

DT2202/102




Date : 02/05/2018

Press the metallic runners against the adjusting gauge (Image 24) then tighten screws

H M10 at 5 daN.m. Strongly maintain runners on the reference plane while tightening.

Image 24 : Adjust and tighten the runners

Then, simulate the crossing of the pantograph by sliding a pantograph gauge under the

contact wire towards the stainless steel runners and vice versa. The transition must be

imperceptible (Image 25).

Block the counter-nut of the adjusting screw and repeat these operations on the other

side of the section insulator.

The transition contact wire / runners must be imperceptible. This transition area where

the contact wire and the two runners are aligned on a same line must be behind the

anchoring clamp.

Torque: - H M10 screws : 5 daN.m

Image 25 : Check the adjustment of the section insulator



Instruction manual

DT2202/102




Date : 02/05/2018

9. Adjusting of parallelism of section insulator with regard to track level

First set turnbuckles, they must be adjusted in their middle positions and then adjust

suspension droppers with the good length, Image 26.

Image 26 : Suspension dropper

Turnbuckle

Thimble and crimped

sleeve

Pin



Instruction manual

DT2202/102




Date : 02/05/2018

In order to recover cant of the track, use the stagger, height and cant measurement

device as below, Image 27.

Image 27 : Position the stagger and height measurement device on the track

The Image 28 after, illustrate the stagger of the contact wire. It can be easily measured

using the ruler on this specific device.

The maximal authorized stagger ± 50 mm (see paragraph II.1 page 8).

Stagger, height and cant measurement

device

90°

Track

Section insulator



Instruction manual

DT2202/102




Date : 02/05/2018

Image 28 : Measure of the stagger with no cant

Using this specific device, it is easy to shift the cant of the track on the section insulator.

Image 29 : Measure of the stagger with cant

Vertical axis

Track axis

Section insulator axis

Stagger

Track axis

Section insulator

axis

Stagger



Instruction manual

DT2202/102




Date : 02/05/2018

Adjust the height of the device by putting in contact the ruler with the contact wire. Then

position the device under the section insulator in order to be in contact with the stainless

steel runners (Image 30).

Image 30 : Adjust the device

Control the length of the droppers by acting on turnbuckles in order that runners lay

naturally on the ruler.

The suspensions must be neither loosen nor too tight. Then put on the pin on each

turnbuckle to not let them rotate anymore.

Image 31 : Adjust the length of the droppers acting on the turnbuckles



Instruction manual

DT2202/102




Date : 02/05/2018

Repeat these operations on the other side of the section insulator, finally check the

setting (Image 32) and block the counter-nuts of the turnbuckles.

Contact plan of the section insulator must be parallel to the track level.

Image 32 : Repeat adjusting operation on the other side of the section insulator

Tighten definitely the spacer claws with a torque. For that, tighten the HFR M10 nuts

at 5 daN.m.



Instruction manual

DT2202/102




Date : 02/05/2018

The section insulator is now properly installed. Well-adjusted, it must look like the

illustration of Image 33 below :

Image 33 : Section insulator with a messenger insulator



Instruction manual

DT2202/102




Date : 02/05/2018

III. Final checking

1) Check that section insulator is correctly assembled.

2) Ensure that all screws, counter-nuts, clamps and turnbuckles are blocked.

3) Check the adjustment of the section insulator by simulating the passage

of the pantograph by means of a pantograph gauge or a ruler.

4) Verify that no kinks are present on the contact wire close to the section

insulator. Straighten out the contact wire if necessary.

5) During installation and / or replacement of a section insulator, according

to additional weight of the section insulator in the span, it might be

necessary to adjust length of some droppers.



Instruction manual

DT2202/102




Date : 02/05/2018

IV. Maintenance et inspection

Periodicity: Once a year inspection maintenance must be carried out.

Each time:

1. Control visually general aspect of the section insulator.

2. Make sure that no damage or shocks on the section insulator have

been generated by pantograph crossing.

3. Verify section insulator adjustment by simulating the passage of the

pantograph by means of a pantograph gauge or a ruler.

4. Check that stainless steel runners wear is uniform; one runner

more worn than another means a bad adjustment.

5. Maximal admissible wear is 5 mm. So as soon as

the thickness of the runner is 3 mm they must

be replaced.

6. Control longitudinal and transversal parallelism of the section insulator with

regard to track level, correct if necessary.

7. Check that all screws, counter-nuts, clamps and turnbuckles are

blocked.

8. Finally, clean the section insulator with soapy water if necessary.

Nota :

In case of observation of a grave deterioration affecting energy collection

or the reliability of the section insulator it is necessary to replace the unit.

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