RPS TracFeed DZK Manual

Push-pull cable

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

Download this manual

TracFeed

DZK

Push-pull cable

MANUAL

Version 1.0

English

L Read the manual before carrying out any work.

Table of Contents

Need help?

Do you have a question about the TracFeed DZK and is the answer not in the manual?

Questions and answers

Summary of Contents for RPS TracFeed DZK

Page 1 ® TracFeed Push-pull cable MANUAL Version 1.0 English L Read the manual before carrying out any work.
Page 2 Rail Power Systems GmbH Garmischer Str. 35 81373 Munich GERMANY Telephone: +49 89 41999-0 Fax: +49 89 41999-270 Email: info@rail-ps.com Internet: www.rail-ps.com Document number: 3EGF202665D Translation of the original TracFeed ® DZK Push-pull cable 11.12.2024...
Page 3: Supplemental Directives
Supplemental directives Purpose of this manual This manual enables safe and efficient handling of the product. The manual is a component of the product and must be kept in the vicinity of the product where personnel can access it at all times. Scope This manual applies to the following product types: TracFeed...
Page 4 Part 1: Power supply systems Part 2: Lighting systems Tests for electrical systems and equipment Accident prevention regulation “Electrical installations and equipment” www.dguv.de (DGUV regulation 3) Assembly drawings for applicable tightening torques: RPS document number 3EGF002458D0025 TracFeed ® DZK Push-pull cable 11.12.2024...
Page 5 Supplemental directives Conformity Depending on the project requirements, different EU Directives, standards and regulations apply. This can affect the content of the declaration of conformity. For this reason, the declaration of con- formity is provided on a product-specific basis when the project is implemented. ®...
Page 6: Table Of Contents
Table of contents Table of contents Overview................8 Safety................. 11 2.1 Symbols used.............. 11 2.2 Intended use............... 13 2.3 Work and danger zone..........14 2.4 Owner’s responsibility..........14 2.5 Personnel requirements..........16 2.6 Personal protective equipment........18 2.7 Dangers..............20 2.8 Behaviour in the event of fires and accidents.....
Page 7 Table of contents 6.6.1 Assembling the push-pull cable on the switch dis- connector/earthing switch........44 6.6.2 Assembling the push-pull cable on the remote motor drive............... 46 6.7 Adjusting the push-pull cable........47 6.7.1 Adjusting the push-pull cable on the remote motor drive and disconnector without earth contact/ earthing switch............
Page 8: Overview
Overview Overview ® Fig. 1: System overview TracFeed DZK push-pull cable on the pole Switch disconnector (or earthing switch) ® TracFeed DZK push-pull cable Cable supports on the switch disconnector Cable supports on the remote motor drive Pole fastening Remote motor drive Brief description ®...
Page 9 Overview ® The TracFeed DZK push-pull cable can be used instead of a shift linkage. Field of application ® The TracFeed DZK push-pull cable is designed for use in over- head contact systems in tunnels and for outdoor use. ® The TracFeed DZK push-pull cable can be used with all variants of switch disconnector/earthing switches and remote motor drives...
Page 10 Overview Accessories ® The following accessories are available for the TracFeed push-pull cable: Tab. 1: Fittings for attachment at the pole Designation Order number Pole cable support 3EGF021564 Disconnector/earthing 3EGF021562 switch cable support One-sided hinge joint 3EGF020936 Clevis end fitting 3EGF020739 Remote motor drive 3EGF030212...
Page 11: Safety
Safety Symbols used Safety 2.1 Symbols used Safety instructions Safety instructions are indicated by symbols in this manual. The safety instructions are introduced by signal words that express the extent of the hazard. DANGER! This combination of symbol and signal word indi- cates an imminently hazardous situation that will result in death or severe injuries unless avoided.
Page 12 Safety Symbols used DANGER! This combination of symbol and signal word indi- cates hazards due to electric voltage. Failure to comply with these safety instructions can result in severe to fatal injuries. The following symbol is used in safety instructions to draw atten- tion to special dangers due to working at height: WARNING! This combination of symbol and signal word indi-...
Page 13: Intended Use
Safety Intended use Example: Unscrew the screw. CAUTION! Risk of pinching at the lid! Close the lid carefully. Tighten the screw. Tips and recommendations This symbol highlights useful tips and recommen- dations as well as information for efficient and fault-free operation. Bullet points In order to highlight instructions, results, lists, references and other elements, the following markings are used in this manual:...
Page 14: Work And Danger Zone
Safety Owner’s responsibility Improper use DANGER! Danger due to improper use. Improper use of the ® TracFeed DZK push-pull cable can result in dan- gerous situations. – Install and operate the ® TracFeed DZK push-pull cable only in accord- ance with the technical data, the usage limi- tations, the contractually agreed specifications and the delivery conditions with the supplied accessories.
Page 15 Safety Owner’s responsibility In addition to the safety instructions in this manual, the applicable safety, accident prevention and environmental regulations for the ® area in which the TracFeed DZK push-pull cable is used must be complied with. The following applies in particular: The owner must keep themselves informed of the appli- cable occupational safety regulations and carry out a risk analysis to determine additional hazards that arise due to...
Page 16: Personnel Requirements
Safety Personnel requirements Furthermore, the owner is responsible for ensuring that the product is always in perfect technical condition. The following therefore applies: The owner must have the product inspected for functionality and completeness by trained qualified personnel at regular intervals.
Page 17 Safety Personnel requirements Qualification Personnel require the following qualifications: Authorised service personnel Authorised service personnel have been authorised by Rail Power Systems GmbH to perform servicing activities on the contact line system. The manufacturer’s service personnel can prove their authorisation by presenting a dated certificate issued by Rail Power Systems GmbH that specifically names the personnel in question.
Page 18: Personal Protective Equipment
Safety Personal protective equipment Earthing and short-circuiting Performing certain maintenance activities Unauthorised persons WARNING! Risk of fatal injury to unauthorised persons due to dangers in the vicinity of the working area! Unauthorised persons who do not meet the requirements described here are not aware of the dangers in the vicinity of the working area.
Page 19 Safety Personal protective equipment Description of personal protective The personal protective equipment is described below: equipment High-vis clothing Wear high-vis clothing to make you more visible to others. Wear high-vis clothing in particular when working in the vicinity of rail tracks.
Page 20: Dangers
Safety Dangers 2.7 Dangers Voltage DANGER! Risk of fatal injury due to electric voltage! Potentially fatal voltages occur on railway systems and in the vicinity of overhead contact lines. – Permit only qualified electricians to perform work on live components. Personnel must be sufficiently informed of the potential hazards that may occur in railway operations.
Page 21 Safety Dangers Working in the vicinity of rail tracks DANGER! Risk of fatal injury in the vicinity of rail tracks! Carelessness when working in the vicinity of rail tracks can result in severe to fatal injuries. – Only perform work on overhead contact lines in favourable weather conditions.
Page 22: Behaviour In The Event Of Fires And Accidents
Safety Behaviour in the event of fires and accidents Heavy weight WARNING! Risk of injury due to heavy weight! Lifting or moving parts with a high dead weight could cause back pain and injuries. – Do not lift heavy parts alone. –...
Page 23: Environmental Protection
Safety Environmental protection If a fire breaks out: If there is no risk to your own health, fight the fire with fire-extinguishing equipment and continue fighting the fire until the fire brigade arrives. Inform the person responsible at the operating site. Clear access routes for emergency vehicles.
Page 24: Technical Data
Technical data Dimensions Technical data 3.1 Dimensions Diameter Specification Value Unit Nominal diameter of 17.6 mm push-pull cable Connecting bolt 26 mm diameter Cable lengths Order number Cable length [mm] 3EGF030020 1 500 3EGF030021 2 250 3EGF030022 3 000 3EGF030023 3 750 3EGF030024 4 500...
Page 25: Mechanical Values
Technical data Plate 3.2 Mechanical values Specification Value Unit Nominal force ten- 4 500 N sile Input force pressure, 3 150 N max. Cable stroke 203 to 208 mm Minimum bending 300 mm radius 3.3 Ambient conditions Specification Value Unit Temperature range -30 ...
Page 26: Transport, Packaging And Storage
Transport, packaging and storage Symbols on the packaging Transport, packaging and storage 4.1 Inspection on delivery On receipt, immediately inspect the delivery for completeness and transport damage. Proceed as follows in the event of externally apparent transport damage: Do not accept the delivery or accept it only conditionally. Note the extent of damage on the transport documents or on the carrier’s delivery note.
Page 27: Transporting The Packages
Transport, packaging and storage Transporting the packages 4.3 Transporting the packages Improper transport NOTICE! Property damage due to improper transport! Packages can fall or topple over if not transported correctly. This can result in extensive property damage. – When unloading the packages on arrival, as well as during transport, proceed with caution and observe the symbols and instructions on the packages.
Page 28: Storage Of The Packages
Transport, packaging and storage Packaging 4.4 Storage of the packages Store the packages under the following conditions: Do not store outdoors. Store in dry and dust-free conditions. Do not expose to aggressive media. Avoid mechanical shocks. Storage temperature: -30 to +50 °C Relative humidity: £...
Page 29: Ensuring That The Installation Is Dead
Ensuring that the installation is dead Earthing and short-circuiting Ensuring that the installation is dead Personnel: Qualified electrician for high and medium voltage Protective equip- Safety helmet with visor ment: Protective clothing Protective gloves Safety footwear 5.1 Isolate from the power supply The part of the system on which work is to be performed must be disconnected from all infeeds.
Page 30: Cover Or Shield Adjacent Live Parts
Ensuring that the installation is dead Cover or shield adjacent live parts. 5.5 Cover or shield adjacent live parts. If it is not possible to disconnect parts of the system in the vicinity of the work location, additional safety measures must be taken before commencing work, as defined for “working near live parts”.
Page 31: Assembly
Assembly Requirements for the installation location Assembly 6.1 Tools and materials Tools The following tools are required during assembly: Hand tools Triangular wrench SW 10 - 22 Lever/changeover ratchet with torque limitation, up to 200 Nm Folding rule, 2 m Marking tool (felt-tip pin) Voltage tester Suitable for the system’s operating voltage.
Page 32 Assembly Requirements for the installation location Inserting the thread into the switch disconnector The correct position of the threads for the cable ® support ensures the alignment of the TracFeed DZK push-pull cable with the adjusting lever of the switch disconnector. The position of the threads may vary depending on the switch disconnector type.
Page 33 Assembly Requirements for the installation location Inserting the thread into earthing switch The correct position of the threads for the cable ® support ensures the alignment of the TracFeed DZK push-pull cable with the adjusting lever of the earthing switch. The position of the threads may vary depending on the type of earthing switch.
Page 34: Preparing The Push-Pull Cable For Assembly
Assembly Preparing the push-pull cable for assembly 6.4 Preparing the push-pull cable for assembly NOTICE! Property damage due to damaged bellows! Bellows protect sensitive components of the Trac- Feed ® DZK push-pull cable from weather influ- ences and damage. Bellows can be damaged in contact with oils and fats.
Page 35 Assembly Preparing the push-pull cable for assembly The U-bolts are already lubricated at the factory. Fig. 6: Clevis end fitting for assembly on the switch disconnector Connect the TracFeed ® DZK push-pull cable (Fig. 6/3) on one side to the clevis end fitting (Fig. 6/1) (3EGF020739). Hand-tighten the nuts of the U-bolts (Fig.
Page 36: Assembling Cable Supports For Push-Pull Cable
Assembly Assembling cable supports for push-pull cable Fig. 7: One-sided hinge joint for assembly on the remote motor drive ® Connect the TracFeed DZK push-pull cable (Fig. 7/1) on the other side to the one-sided hinge joint (Fig. 7/3) (3EGF020936). Hand-tighten the nuts of the U-bolts (Fig.
Page 37 Assembly Assembling cable supports for push-pull cable NOTICE! Property damage due to faulty assembly! Faulty assembly of the TracFeed ® DZK push-pull cable can result in damage to the switch discon- nector/earthing switch and remote motor drive. – Note the assembly sequence. –...
Page 38: Assembling The Cable Supports On The Remote Motor Drive
Assembly Assembling cable supports for push-pull cable > Assembling the cable supports on the remote motor drive 6.5.1 Assembling the cable supports on the remote motor drive Fig. 8: Cable supports on the remote motor drive Assemble the cable support (Fig. 8/2) on the remote motor drive (Fig.
Page 39: Assembling The Cable Support On The Switch Disconnector/Earthing Switch
Assembly Assembling cable supports for push-pull cable > Assembling the cable support on the switch disconnector/earthing switch 6.5.2 Assembling the cable support on the switch disconnector/earthing switch Fig. 9: Example: Cable supports on the switch disconnector Assemble the cable support (Fig. 9/1) (3EGF021210) at the base of the switch disconnector/earthing switch (Fig.
Page 40: Assembling The Cable Supports On The Disconnector
Assembly Assembling cable supports for push-pull cable > Assembling the cable support on the pole 6.5.3 Assembling the cable supports on the disconnector Fig. 10: Cable supports on the disconnector Assemble the cable support (Fig. 10/3) at the base of the disconnector (Fig.
Page 41 Assembly Assembling cable supports for push-pull cable > Assembling the cable support on the pole Fig. 11: Cable supports on the pole Install the first cable support (Fig. 11) on the remote motor drive approx. 1 m away from the end of the cable support. Assemble the other cable supports approx.
Page 42: Assembling Cable Supports On The Wall
Assembly Assembling cable supports for push-pull cable > Assembling cable supports on the wall 6.5.5 Assembling cable supports on the wall Fig. 12: Cable supports for the wall Install the first cable support (Fig. 12) on the remote motor drive approx. 1 m away from the end of the cable support. Assemble the other cable supports approx.
Page 43: Assembling The Push-Pull Cable
Assembly Assembling the push-pull cable 6.6 Assembling the push-pull cable NOTICE! Property damage due to faulty assembly! ® Faulty assembly of the TracFeed DZK push-pull cable can result in damage to the switch discon- nector/earthing switch and remote motor drive. –...
Page 44: Assembling The Push-Pull Cable On The Switch Disconnector/Earthing Switch
Assembly Assembling the push-pull cable > Assembling the push-pull cable on the switch disconnector/earthing switch The cable supports on the remote motor drive and on the switch disconnector/earthing switch are assembled. Ä Chapter 6.5.1 ‘Assembling the cable supports on the remote motor drive’...
Page 45 Assembly Assembling the push-pull cable > Assembling the push-pull cable on the switch disconnector/earthing switch ® Fig. 13: TracFeed DZK push-pull cable on the circuit breaker ® Pull TracFeed DZK push-pull cable through the opening of the base of the switch disconnector/earthing switch. Assemble and brace the clevis end fitting (3EGF020739) on the TracFeed ®...
Page 46: Assembling The Push-Pull Cable On The Remote Motor Drive
Assembly Assembling the push-pull cable > Assembling the push-pull cable on the remote motor drive 6.6.2 Assembling the push-pull cable on the remote motor drive Route and fasten the TracFeed ® DZK push-pull cable from the remote motor drive to the switch disconnector/earthing switch through the cable supports.
Page 47: Adjusting The Push-Pull Cable
Assembly Adjusting the push-pull cable ® Fig. 16: TracFeed DZK push-pull cable on the remote motor drive ® Assemble the TracFeed DZK push-pull cable (Fig. 16/1) on the lever of the remote motor drive (Fig. 16/3). Tighten the nuts of the U-bolts (Fig. 16/2) to torque MA = 56 Nm.
Page 48: Adjusting The Push-Pull Cable On The Remote Motor Drive And Disconnector Without Earth Contact/Earthing Switch
Assembly Adjusting the push-pull cable > Adjusting the push-pull cable on the remote motor drive and disconnector without earth contact/ earthing switch 6.7.1 Adjusting the push-pull cable on the remote motor drive and disconnector without earth contact/earthing switch Adjust the push-pull cable on the cable support of the remote motor drive ®...
Page 49: Adjusting The Push-Pull Cable On The Remote Motor Drive And Disconnector With Earth Contact/Earthing Switch
Assembly Adjusting the push-pull cable > Adjusting the push-pull cable on the remote motor drive and disconnector with earth contact/earthing switch If the adjustment path is not sufficient (contact blade does not dip into the contact springs), screw on a spacer plate and readjust.
Page 50: Final Checks
Assembly Final checks 6.8 Final checks Check and acceptance The fittings can be checked and accepted together with the checks and acceptance for other installa- tions, such as: – Foundations – Poles – Earthing clamps – Track and rail bonds For the final inspections of the test and inspection plan (Doc.
Page 51: Preventive Servicing
Preventive servicing Maintenance plan > Extraordinary check Preventive servicing 7.1 Maintenance plan Interval Personnel 24 months State check Z Authorised service personnel Ä Chapter 7.1.1 ‘State check Z’ on page 51 After extraordinary Extraordinary check Authorised service events personnel Ä Chapter 7.1.2 ‘Extraordinary check’ on page 51 7.1.1 State check Z The inspection of the TracFeed ®...
Page 52: Corrective Servicing
Corrective servicing Possible faults Corrective servicing 8.1 Behaviour in the event of faults If faults occur increasingly, reduce the maintenance intervals accordingly. If faults occur and they cannot be rectified with the help of the Ä ‘Technical customer information below, contact the manufacturer service’...
Page 53: Replacing The Bellows On The Push-Pull Cable
Corrective servicing Replacing the bellows on the push-pull cable Fault description Cause Remedy The bellows of Bellows are worn. Replace the bellows. the TracFeed ® Ä Chapter 8.3 ‘Replacing the bellows on the push-pull push-pull cable is cable’ on page 53 damaged.
Page 54 Corrective servicing Replacing the bellows on the push-pull cable ® The bellows is attached to the TracFeed DZK push-pull cable with an adapter, a hose clamp and two cable ties. The adapter is secured with a liquid screw lock (Loctite). CAUTION! Risk of burning due to hot surface! Do not touch heated parts without heat-...
Page 55: Disconnecting The Connection Between The Push-Pull Cable And The Remote Motor Drive
Corrective servicing Disconnecting the connection between the push-pull cable and the remote motor drive 8.4 Disconnecting the connection between the push-pull cable and the remote motor drive Fig. 18: Disassembling the TracFeed ® DZK push-pull cable from the remote motor drive Loosen the nuts on the U-bolts (Fig.
Page 56 Corrective servicing Disconnecting the connection between the push-pull cable and the remote motor drive ® Dismantle the TracFeed DZK push-pull cable from the cable support of the remote motor drive (Fig. 19/1). ð The TracFeed ® DZK push-pull cable is no longer con- nected to the remote motor drive.
Page 57: Spare Parts
Spare parts Spare parts Incorrect spare parts WARNING! Risk of injury due to the use of incorrect spare parts! The use of incorrect or defective spare parts can cause dangers for personnel and result in damage, malfunctions or total failure. –...
Page 58: Disassembly And Disposal
Disassembly and disposal Disassembly Disassembly and disposal ® At the end of its useful life, the TracFeed DZK push-pull cable has to be disassembled and disposed of in an environmentally friendly manner. 10.1 Disassembly Improper disassembly WARNING! Risk of injury due to improper disassembly! Stored residual energy, angular components, points and corners can cause injuries.
Page 59: Disposal
Disassembly and disposal Disposal 10.2 Disposal At the end of its useful life, the device has to be disassembled and disposed of in an environmentally friendly manner. If no return or disposal agreement was signed, send the disassem- bled components for recycling: Have metals scrapped.
Page 60: Glossary
Glossary Glossary The term “alternating current” is used to refer to AC current as well as AC voltage. The term “direct current” is used to refer to DC current as well as DC voltage. Earthing Earthing establishes a defined reference potential or equipo- tential loading.
Page 61: Index
Index Index Dead installation ......29 earthing and short-circuiting ....29 Accessories .
Page 62 Index Limitation of liability ......3 Safety ......11, 20, 21, 22 Loads .
Page 63 Index Work range ......14 Working in the vicinity of rail tracks ... 20 Weight .
Page 64: Appendix
Appendix Appendix TracFeed ® DZK Push-pull cable 11.12.2024...
Page 65 Appendix Contents Drives and switches ............66 Checklists and logs ............68 B.1 Training log ..............68 11.12.2024 TracFeed ® DZK Push-pull cable...
Page 66: A Drives And Switches
Drives and switches Drives and switches Remote motor drives Order number Designation Type 3EGF020334 Remote motor drive 230 V AC 1.9-1, for OLSP systems 3EGF020333 Remote motor drive 230 V AC 1.13-1 3EGF021401 Remote motor drive 110 V DC 1.22-1 3EGF021394 Remote motor drive 230 V AC 1.23, with triangular actuation...
Page 67 Drives and switches Order number Designation Design 3EGF012132 15 kV disconnector With vacuum extinguishing chamber 11.12.2024 TracFeed ® DZK Push-pull cable...
Page 68: B Checklists And Logs
Checklists and logs Checklists and logs Training log Personnel must be trained by the owner on a regular basis. A log must be kept of this training to enable better tracking. Date Type of training Name of the Signature of Training pro- Signature of trainer trainee...