RPS TracFeed SFA User manual

MANUAL
Version 1.1
English
L Read the manual before carrying out any work.
TracFeed® SFA
Electromechanical remote motor drive

Translation of the original
Rail Power Systems GmbH
Garmischer Strasse 35
81373 Munich
GERMANY
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.rail-ps.com
Document number: 3EGF002475D0014-en
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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.
This manual applies to the following product types:
nTracFeed® SFA – type 1.13-1 stand-alone version
nTracFeed® SFA – type 1.9-1 DB version OLSP
nTracFeed® SFA – type 1.11-1
nTracFeed® SFA – type 1.22-1
nTracFeed® SFA – type 1.23
Illustrations in this manual are intended for basic understanding
and may differ from the actual style.
This manual is addressed to the following target groups:
nOwner
nAssembly personnel
nLicensed electrician
nAuthorised service personnel
nInstructed person responsible for packaging and transport work
For more detailed information regarding target
groups and the qualifications they require for the
work described in this manual, see Ä ‘Qualifica-
tion’ on page 19.
Purpose of this manual
Scope
Illustrations
Target group
Supplemental directives
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All the specifications and information in this manual were compiled
in consideration of the applicable standards and regulations, the
best available technology and our many years of expertise and
experience.
The manufacturer accepts no liability for damage due to:
nFailure to comply with this manual
nUse contrary to the intended use
nUse of untrained personnel
nUnauthorised modifications
nTechnical modifications
nUse of non-approved spare parts
In the case of special designs, if additional order options are
chosen or due to the latest technical changes, the actual scope of
supply may deviate from the explanations and information given
here.
The obligations agreed in the delivery contract, the manufacturer’s
general terms and conditions and delivery conditions, and the
applicable statutory regulations at the time of the signing of the
contract shall all apply.
The contents of this manual are protected by copyright and
intended solely for end customers.
They may be used within the context of the intended use. Any use
beyond this is not permitted without the written authorisation of Rail
Power Systems GmbH.
The accompanying documents must also be observed in addition
to this manual. Strictly follow the instructions and information they
contain.
NOTICE!
Find out about country-specific regulations and
take these into account.
List of applicable standards and regulations
EN 50122-1
IEC 62128-1
Railway applications – Fixed installations – Electrical safety, earthing and the return
circuit
Part 1: Protective provisions against electric shock
EN 50122-3
IEC 62128-3
Railway applications – Fixed installations – Electrical safety, earthing and the return
circuit
Part 3: Mutual interaction of alternating current and direct current traction systems
EN 50110-1 Operation of electrical installations
Limitation of liability
Copyright
Accompanying documents
Supplemental directives
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List of applicable standards and regulations
EN 50123-1 Railway applications – Fixed installations; D.C. switchgear
Part 1: General
EN 50119 Railway applications – Fixed installations – Electric traction overhead contact lines
Additional project documentation Note
Technical rules for electrical systems
according to the German Federal Regulations on the construction and opera-
tion of light rail transit systems (BOStrab)
Only applicable in Germany
Technical Regulations for Electrical Systems (TR EA):
nPart 1: Power supply systems
nPart 2: Lighting systems
Tests for electrical systems and equipment
Accident prevention regulation “Electrical installations and equipment”
(DGUV regulation 3)
www.dguv.de
Assembly drawings for applicable tightening torques:
nRPS document number 3EGF002458D0025
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.
The TracFeed® SFA – remote motor drives are homogenised in
accordance with EC Low Voltage Directive 2006/95/EC and EN
61439-1:2009 and are certified in accordance with the EC design-
examination certificate 3EGF002090D0016.
Date Revision Change
21/06/2021 1.0 Created
17/08/2022 1.1 SFA types expanded
Conformity
Revision table
Supplemental directives
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Knowledge of the systems and materials and experience of instal-
lation are essential. We recommend arranging for at least one
member of the company’s personnel to be certified by Rail Power
Systems GmbH as the person responsible for the work.
We are happy to answer general queries and inquiries regarding
training.
Tel.: [phone]
Fax: [phone]
Email: [email protected]
In addition, our employees are always interested in acquiring new
information and experience gained from practical application; such
information and experience may help improve our products.
Our technical customer service is available to provide technical
information.
Technical information can be requested from the
sales department at Rail Power Systems GmbH.
Within Germany:
–Email: [email protected]
International sales:
–Email: [email protected]
General queries/training courses
Technical customer service
Supplemental directives
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Table of contents
1 Overview.............................................................................. 9
2 Safety................................................................................. 13
2.1 Symbols used............................................................. 13
2.2 Intended use............................................................... 15
2.3 Work and danger zone............................................... 16
2.4 Owner’s responsibility................................................. 16
2.5 Personnel requirements.............................................. 18
2.6 Personal protective equipment................................... 21
2.7 Dangers...................................................................... 22
2.8 Behaviour in the event of fires and accidents............. 25
2.9 Environmental protection............................................ 25
2.10 Safety devices.......................................................... 26
2.10.1 Location of the safety devices............................... 26
2.10.2 Description of the safety devices........................... 26
3 Technical data................................................................... 28
3.1 Dimensions and weight............................................... 28
3.2 Connected loads......................................................... 28
3.3 Ambient conditions..................................................... 29
3.4 Rating plate................................................................. 29
3.5 Labelling..................................................................... 30
4 Transport, packaging and storage.................................. 33
4.1 Inspection on delivery................................................. 33
4.2 Symbols on the packaging.......................................... 33
4.3 Transporting the packages......................................... 34
4.4 Storage of the packages............................................. 35
4.5 Packaging................................................................... 35
5 Ensuring that the installation is dead............................. 37
5.1 Isolate from the power supply..................................... 37
5.2 Securing against re-connection.................................. 37
5.3 Establishing a dead installation.................................. 37
5.4 Earthing and short-circuiting....................................... 37
5.5 Cover or shield adjacent live parts.............................. 38
6 Assembly........................................................................... 39
6.1 Tools and materials..................................................... 39
6.2 Requirements for the installation location................... 40
6.3 Assembly preparation................................................. 40
6.4 Assembly.................................................................... 42
6.4.1 Assembly on a lattice steel mast or flat-frame
mast......................................................................... 42
6.4.2 Assembly on a concrete pole with embedded
threaded sleeves..................................................... 44
6.4.3 Assembly on a wall or in tunnels............................. 45
Table of contents
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6.4.4 Assembly of the force-displacement transmission
device...................................................................... 46
6.4.5 Connecting the force-displacement transmission
device by means of a shift linkage........................... 46
6.5 Electrical connection................................................... 47
6.5.1 Connecting the electromechanical remote motor
drive......................................................................... 47
6.5.2 Connecting the terminal allocation........................... 49
6.6 Final checks................................................................ 49
6.6.1 Mechanical tests and stroke setting......................... 49
6.6.2 Electrical measurements and function tests............ 50
7 Commissioning................................................................. 54
7.1 Prerequisites............................................................... 54
7.2 Putting into operation.................................................. 54
8 Preventive servicing......................................................... 55
8.1 Maintenance plan....................................................... 55
8.1.1 State check Z........................................................... 55
8.1.2 Lubricate the gear spindle....................................... 56
8.1.3 Extraordinary check................................................. 56
9 Corrective servicing......................................................... 57
9.1 Behaviour in the event of faults.................................. 57
9.2 Possible faults............................................................. 57
9.2.1 Replace tooth belt.................................................... 58
9.2.2 Replacing the rectifier.............................................. 59
9.2.3 Replacing the motor................................................. 60
9.3 Commissioning after clearance of a fault.................... 61
10 Spare parts........................................................................ 62
11 Decommissioning, disassembly and disposal.............. 63
11.1 Decommissioning...................................................... 63
11.2 Disassembly.............................................................. 64
11.3 Disposal.................................................................... 65
12 Glossary............................................................................. 67
13 Index................................................................................... 69
Appendix............................................................................ 72
A Schematic diagrams ........................................................ 74
B Checklists and logs ......................................................... 81
C Directory of other documents and descriptions ........... 86
D List of drawings stated in the text .................................. 87
E Information about the order ............................................ 88
Table of contents
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1 Overview
Fig. 1: Overview of TracFeed® SFA outside
1 Warning sign
2 Enclosure door
3 Lock
4 Pressure equalisation nozzle
5 Crank cover
6 “ON/OFF” label
7 Cable entry
8 Plate
9 Fastening bolt
10 Adjusting lever
11 “ON/OFF” label
External overview
Overview
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Fig. 2: Overview of TracFeed® SFA inside
1 Cable entry
2 Enclosure seal
3 Terminal strip X1
4 Limit switch on the gear unit
5 Tooth belt
6 Direct current motor
7 Power contactor K1
8 Power contactor K2
9 Rectifier
10 Door contact
11 Overcurrent relay K3
12 Capacitor
13 “ON/LOCKED” mode selection switch
14 Spindle gears
15 Crank cover
16 Crank cam
17 Adjusting lever
18 PE connection (door)
The X1 terminal strip in the enclosure is used for
the electrical connection. Note the schematic dia-
gram!
The TracFeed® SFA remote motor drive makes it possible to acti-
vate the switch disconnectors and earthing switches installed on
the pole tips for intercity and mass transit overhead contact sys-
tems.
Internal overview
Short description
Overview
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The TracFeed® SFA remote motor drive is installed on the contact
line pole and it is connected to a switch via a final controlling ele-
ment. A shift linkage provides the mechanical connection between
the TracFeed® SFA remote motor drive and the switch’s adjusting
lever.
The TracFeed® SFA remote motor drive is driven by a direct cur-
rent motor. Power transmission is via a tooth belt, with the power
then converted into a linear motion by means of a threaded
spindle. The linear motion of the threaded spindle creates a stroke
at the adjusting lever. The stroke of the adjusting lever can be
selected as 100 or 200 mm.
The TracFeed® SFA remote motor drive can be moved to its
default position using the crank handle.
The TracFeed® SFA is designed for use in the outdoor area of
overhead contact line systems. The drive meets the requirements
of DIN VDE 0100 and the technical regulations of Deutsche Bahn
AG.
Order number Designation
3EGF020333 TracFeed® SFA – type 1.13-1 stand-alone
version
3EGF020334 TracFeed® SFA – type 1.9-1 DB version
OLSP
(built-in miniature circuit breaker)
3EGF021251 TracFeed® SFA – type 1.11-1
The full scope of supply is specified in the contrac-
tual delivery and performance specifications or the
resultant detailed design. The scope of supply for a
delivery is documented by means of delivery notes
and packing lists.
The following accessories are available for the TracFeed® SFA:
Order number Designation
Available on request Second key
Available on request Square socket key
Available on request Fastening material for wall or
pole mounting
Field of application
Scope of supply
Accessories
Overview
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Order number Designation
Available on request Short-circuit signalling relay
3EGF002076 Crank handle
Overview
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2 Safety
2.1 Symbols used
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.
WARNING!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that could
result in death or severe injuries unless avoided.
CAUTION!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that could
result in minor or slight injuries unless avoided.
NOTICE!
This combination of symbol and signal word indi-
cates a potentially hazardous situation that could
result in damage to property unless avoided.
ENVIRONMENT!
This combination of symbol and signal word indi-
cates potential hazards to the environment.
The following symbol is used in safety instructions to draw atten-
tion to special dangers due to electric voltage:
Safety instructions
Special safety instructions
Safety
Symbols used
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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-
cates hazards due to working on ladders or lifting
platforms without due care and attention.
Failure to comply with these safety instructions can
result in severe injuries.
The following symbol is used in safety instructions to draw atten-
tion to special dangers due to falling objects:
WARNING!
This combination of symbol and signal word indi-
cates hazards due to falling objects.
Failure to comply with these safety instructions can
result in severe injuries.
The following symbol is used in safety instructions to draw atten-
tion to special dangers due to lifted loads:
WARNING!
This combination of symbol and signal word indi-
cates hazards due to load-lifting procedures and
suspended loads.
Failure to comply with these safety instructions can
result in severe injuries.
Safety instructions may refer to specific, individual instructions.
Such safety instructions are incorporated into the instructions so
that they do not interrupt the reading flow when carrying out the
activity. The signal words described above are used.
Safety instructions in operating
instructions
Safety
Symbols used
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Example:
1. Unscrew the screw.
2.
CAUTION!
Risk of pinching at the lid!
Close the lid carefully.
3. Tighten the screw.
This symbol highlights useful tips and recommen-
dations as well as information for efficient and
fault-free operation.
In order to highlight instructions, results, lists, references and other
elements, the following markings are used in this manual:
Marking Explanation
Step-by-step instructions
ðResults of actions
References to sections of this manual and
to other applicable documents
Lists without a specific order
2.2 Intended use
The TracFeed® SFA remote motor drive (referred to in the fol-
lowing as TracFeed® SFA) is used to activate the switch discon-
nectors and earthing switches installed on the pole tips for inter-
city and mass transit overhead contact systems. Power
transmission takes place mechanically via an adjusting lever on
the back of the TracFeed® SFA, which is connected to the circuit
breaker or earthing switch by a force-displacement transmission
device.
The TracFeed® SFA is operated and monitored electronically
from a remote location. In the event of a fault, the TracFeed® SFA
can be operated manually using a crank handle.
The TracFeed® SFA has been designed and constructed solely for
the intended use described here.
Tips and recommendations
Bullet points
Safety
Intended use
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The intended use also includes compliance with all the information
in this manual, the information in the other documents provided,
and the documents listed in Ä ‘Accompanying documents’
on page 4.
Any use that exceeds or differs from the intended use shall be con-
sidered improper use.
DANGER!
Danger from improper use.
Improper use of the TracFeed® SFA can result in
dangerous situations.
– Only install and operate the TracFeed® SFA in
accordance with the technical data, the usage
limitations, the contractually agreed specifica-
tions and the delivery conditions with the sup-
plied accessories.
– Do not operate the TracFeed® SFA in areas at
risk of explosion.
– Do not make any unauthorised modifications,
manipulations or conversions.
– Never use the TracFeed® SFA for purposes
other than the connection and segregation of
feeding groups within overhead contact lines.
No claims of any kind will be entertained if such claims result from
improper use.
2.3 Work and danger zone
The work range stretches along the track system and it must be
defined by the person responsible for the work according to which
work is to be carried out.
The danger zone includes adjacent areas because trains may be
travelling on parallel/crossing tracks, for example, and the direct
mounting area at the installation location.
2.4 Owner’s responsibility
The owner is the natural person or legal entity who operates the
product for commercial or economic purposes either for that per-
son’s own use or transfers it to a third party for use and who bears
the legal product liability for the protection of personnel or third par-
ties during operation.
Improper use
Work range
Danger zone
Owner
Safety
Owner’s responsibility
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The TracFeed® SFA is used in the commercial sector. The owner
must therefore comply with statutory occupational safety require-
ments.
In addition to the safety rules in this manual, the applicable safety,
accident prevention and environmental regulations for the area in
which the TracFeed® SFA is used must be complied with.
In this regard, the following applies in particular:
nThe owner must keep themselves informed of the applicable
occupational safety regulations and carry out a risk analysis to
determine additional hazards that arise due to the specific
working conditions at the area in which the TracFeed® SFA is
used. The owner must then implement this information in the
form of manuals governing operation of the TracFeed® SFA.
nThe owner is obliged to confer with the office responsible for
railway operation (control room) before beginning any work and
to jointly agree on safety measures (e.g. flagmen or line clo-
sure). Before commencing work, ensure that the safety meas-
ures are effective.
nThe owner must sufficiently inform personnel of potential dan-
gers that arise from railway operation and of protective meas-
ures. The owner must instruct personnel to follow the arrange-
ments of the body responsible for railway operation.
nThe owner must clearly lay down and specify responsibilities
with respect to assembly, commissioning, operation, trouble-
shooting and repairs of the TracFeed® SFA.
nThe owner must provide personnel with the necessary protec-
tive equipment and instruct them to wear the necessary protec-
tive equipment.
nThe owner must ensure that all personnel dealing with the
product have read and understood this manual. In addition, the
owner must provide personnel with training and information
regarding hazards at regular intervals.
nThe owner must arrange and operate the product such that it
complies with the local regulations concerning interference
emission and immunity in the event of electrical and magnetic
fields.
nThe owner must arrange the product such that it complies with
the local regulations concerning electrical and magnetic fields
in terms of their effect on people.
nThroughout the period that the TracFeed® SFA is in use, the
owner must assess whether the manuals they have issued
comply with the present status of regulations, and must update
the manuals if necessary.
nThe owner must notify the supervisory authorities without delay
in the event of any accidents in which a person is killed or
severely injured or the product suffers significant damage.
nThe owner must notify the supervisory authorities without delay
in the event of operating incidents that attract public attention.
Owner’s obligations
Safety
Owner’s responsibility
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Furthermore, the owner is responsible for ensuring that the product
is in a technically flawless condition at all times. The following
therefore applies:
nThe owner must have the product inspected for functionality
and completeness by trained qualified personnel at regular
intervals.
nThe owner must have all safety equipment inspected for func-
tionality and completeness by trained qualified personnel at
regular intervals.
2.5 Personnel requirements
DANGER!
Risk of injury if personnel are insufficiently
qualified!
If unqualified personnel perform work on the
system or enter the system’s danger zone, dan-
gers arise that could result in death or severe inju-
ries. In addition, significant property damage may
occur.
– All work must be performed by appropriately
qualified or trained personnel only.
– All work on the electrical system must be per-
formed by appropriately qualified electricians
only.
– Unqualified/untrained personnel must be kept
away from the danger zones.
– Once work on the system is complete, make
sure that no tools are left behind.
The minimum age for persons permitted to work as personnel and
the requirements of employment medical examinations must
comply with the locally applicable statutory regulations of the
country in which the product is used.
Persons with impaired reactions due to, for example, the consump-
tion of drugs, alcohol, or medication are prohibited.
Records must be kept of persons who work on controlling and
monitoring the operating procedure. These records must clearly
show the suitability, training, examination results, supervision,
courses of instruction and training courses for these persons.
When selecting personnel, the applicable age-related and occupa-
tion-related regulations for the operating site must be observed.
Insufficient qualification
General requirements
Safety
Personnel requirements
14.09.2022TracFeed® SFA Electromechanical remote motor drive18

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.
Fitter for contact line installations
Based on their technical training, knowledge, experience and
knowledge of the applicable standards and regulations, fitters are
able to assemble the contact line and they are able to independ-
ently recognise and avoid potential dangers.
Fitters are specially trained for the area of responsibility they are
involved with and know the relevant standards and regulations.
Fitters must comply with the requirements of the applicable legal
regulations for accident prevention.
Qualified electrician
The qualified electrician is able to execute tasks on electrical
equipment and independently detect and avoid any possible dan-
gers thanks to his training, expertise and experience, as well as
knowledge of all applicable regulations.
The qualified electrician has been specially trained for the work
environment in which he is active and is familiar with all relevant
standards and regulations.
Qualified electrician for high and medium voltage
The qualified electrician for high and medium voltage is able to
carry out work on high and medium voltage installations safely due
to their training, experience and knowledge. The qualified electri-
cian for high and medium voltage avoids dangers for themself,
third parties and material property by implementing the measures
for avoiding dangers from the regulations and specifications for
handling high and medium voltage applicable at the operating site
when performing their tasks. The qualified electrician for high and
medium voltage has been trained in relation to the special features
of the Rail Power Systems GmbH product.
In particular, the qualified electrician for high and medium voltage
has the following knowledge, which they can prove by means of a
recognised certificate:
nParticular dangers when handling high and medium voltage
components (e.g. arcing)
nDisconnection and earthing of high and medium voltage com-
ponents
nEnsuring that high and medium voltage components are dead
nReading and understanding circuit diagrams including the
meaning of circuit symbols
nFunction and design of high and medium voltage networks and
railway power supplies
Qualification
Safety
Personnel requirements
14.09.2022 TracFeed® SFA Electromechanical remote motor drive 19

nSpecial features of high and medium voltage with AC and DC
voltage
nOwner’s specifications for disconnection and isolation from the
power supply
On account of the aforementioned verifiable knowledge, the electri-
cian for high and medium voltage is able to carry out the following
activities without endangering themself or third parties:
nOn-site disconnection
nEnsure that the installation is dead
nSwitch controls manually
nEarth and short-circuit
nPerform certain maintenance activities
Trained qualified personnel
Based on their technical training, knowledge, experience and
knowledge of the applicable standards and regulations, trained
qualified personnel are able to perform assembly, operation, trou-
bleshooting and maintenance work on the product and they are
able to independently recognise and avoid potential dangers.
Trained qualified personnel are specially trained for the area of
responsibility they are involved with and know the relevant stan-
dards and regulations.
Trained qualified personnel must comply with the requirements of
the applicable legal regulations for accident prevention.
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. As a
result, unauthorised persons face the risk of
serious injuries or death.
– Keep unauthorised persons away from the
vicinity of the working area.
– If in doubt, talk to persons and instruct them to
leave the working area.
– Interrupt work while unauthorised persons are
in the vicinity of the working area.
The owner must train personnel on a regular basis. A training log is
to be created to improve traceability. At the very least, this log must
include:
nDate of the training
nName of the trainee
nContents of the training
Unauthorised persons
Training
Safety
Personnel requirements
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