Actuator for switching devices in OCL (230 V AC)

1 Purpose

The purpose of this document is to describe objective requirements to the components in such a way that the manufacturer can design, produce, control and deliver in accordance with the Norwegian National Rail Administration’s (NNRA) requirements.

Requirements given in this document shall be delivered when 230 V A.C. actuators to the overhead contact lines are purchased.

2 Scope

This specification shall be mandatory when designing and delivering 230 V A.C. actuators to the overhead contact lines and brackets adapted to NNRA’s installations.

3 Function

Actuators shall provide an operating safe and controlled operating of the switchgear in overhead contact lines.

4 Requirements

In this chapter the requirements to 230 V A.C. actuators is defined in three main sections:

• General requirements to 230 V A.C. actuator
• Technical requirements to 230 V A.C. actuator
• Documentation/tests to 230 V A.C. actuator

In case some general, technical and document/test requirements are extremely cost increasing in relevance to the manufacturers evaluation/assessment of the requirements benefit, we request special response on this in accordance with the tender documentation.

4.1 General requirements to 230 V A.C. actuator

4.1.1 Quality plan

1. The manufacturer should work accordingly to a quality plan which satisfy ISO 9002 or equivalent. A copy of the quality manual shall be delivered to the NNRA with the tender (or as baseline document at technical approval).
2. If subcontractors are used in the production or part production of actuator it is the suppliers responsibility to control the subcontractors quality plan. NNRA shall be entitled to visit both the supplier and subcontractors and if required take a sample survey of the plan.
3. If the supplier finds divergence between descriptions in this document and drawings, the supplier shall make the NNRA aware of this in writing. In advance of production start such points shall be clarified and certified in writing.
4. The manufacturer shall in connection with production of 230 V A.C. actuators draw up a quality plan describing main activities in connection with production included the manufacturers suggestion on procedures to tests and expected results. The quality plan shall give references to relevant specifications and standards.
5. Requirements stated in drawings together with documents referenced in drawings delivered by NNRA shall have precedent of this document.

4.1.2 Lifespan and environment

1. 230 V A.C. actuators should be manufactured in a way that secure minimum period of use of 25 years.
2. 230 V A.C. actuators shall be manufactured in a way that ensures maintenance, disassembling and adjustment without reduction in lifespan.
3. Information on parts that wears and has to be changed frequently shall be stated by the manufacturer in the tender.

4.1.3 Environmental temperature

Actuators shall be robust and reliable in all weather conditions and have a reliable functionality inside a temperature range from -40 to +50 degrees C.

4.1.4 Moisture

Actuators shall fulfil all requirements up to 100 % relative humidity and work in all Norwegian outdoor and indoor environments included tunnels.

1. Degree of density IP 44 for tunnel variant included ventilation/drain sleeve coupling
2. Degree of density IP 43 for outdoor variant included ventilation/drain sleeve coupling

NNRA prefers one variant of actuator to cover all the cases mentioned above.

4.1.5 Dust

Impurities or dust collection from train operation shall not reduce the lifespan, function or performance.

4.1.6 Corrosion

• 230 V A.C. actuators shall be manufactured with materials chosen to be resistant to corrosion.
• Parts that are forged or pressed shall not show any faults or irregularities and shall be free of blisters, fissures or other rolled faults.

4.1.7 Hot dip galvanizing

• Coating thickness for the hot dip galvanizing shall be according [NS-EN ISO 1461]. The manufacturer should evaluate if further corrosion protection is necessary.
• The zinc added to the zinc-bath shall have a purity of at least 98 %
• Zinc dripping shall be removed in a way such as no personal injury will arise

4.1.8 Vibration/suction or pressure forces

• Actuators should have an appropriate design in a manor that vibration/pressure damages do not occurs when trains passes at speeds ≤ 250 km/h. If there is some mechanical limitations regarding vibrations and pressure/suction forces this shall be stated by the manufacturer.
• Minimum loads from train operations that the actuators cabinet shall be dimensioned for is:
  • Pressure force: +1.8 kN/m²
  • Suction force: - 2.4 kN/m²

4.1.9 Interfaces

• The actuator has an interface towards actuating lever for actuators and cable for RTU to remote control.
• The actuator has an interface towards wooden-, concrete- and steel poles.
• The actuator is normally mounted in a height of 1.5 m from top of rail.

See clause Attached drawings.

4.1.9.1 Interface towards steel poles

The actuator shall be equipped with a universal bracket to mount on all of NNRA’s lattice- and girder poles.

4.1.9.2 Interface towards wooden- and concrete poles

Brackets for actuator shall be adapted to fit NNRA’s brackets for wooden- and concrete poles.

4.1.10 Interface towards switchgear

230 V A.C. Actuators shall be adapted to fit NNRA’s already existing switchgear for overhead contact lines.

• Vertical movement/wandering of the actuating lever shall be equal to 120 mm.

4.1.11 Tools/Special tools

1. Mounting, maintenance and operating of actuators should not require special tools. If special tools is necessary this shall be stated in the tender and be attended the deliverance.
2. If necessary the manufacturer shall make procedures for use of special tools.

4.1.12 Requirements of tolerances regarding actuators

Testing and tolerances accordingly following EN norms. [NEK IEC 60060-1] [NEK EN 62271-1]

4.1.13 Design of earthing

1. When mounting actuators on hot dip galvanized steel poles the earthing shall be direct, earthed substructure.
2. It shall additionally be mounted an M12 earthing point to connect to NNRA’s earthing system.
3. For connection of earthing in feeding cable it shall be mounted a PE-terminal insulated form the cabinet with a minimum insulation level of 600 V.

4.1.14 Design of labeling

The actuator shall be labelled with type, date of production, manufacturers company name and optionally catalogue numbers/serial numbers easily visible and of a quality which do not disappear or weakens the construction.

4.1.15 Storage and transport

1. The manufacturer shall make sure that damages on actuator do not appear when handled or during transportation.
2. Actuator shall be delivered packaged in an appropriate way.

4.1.16 Recycling and destruction of components

1. In the tender the manufacturer shall state if the products contains of environmental damaging materials/substances and if so how to handle this both under use and when disposed.
2. The manufacturer shall check the raw material/product against radioactive particles and radiation. The amount of radioactivity and cadmium shall be within the limit allowed by national and international standards.

4.2 Technical requirements to 230 V A.C. actuator

4.2.1 Requirements to driving motor and controlling

1. From the RTU for remote controlling the actuator should be able to be supplied with 230 V A.C. 1-phase and motor currents normally not exceeding 2.5 A. See clause Attached drawings.
2. The actuator shall be able to equip with preceding slow fuses in the area of 4–16 A.
3. The motor shall be secured with motor protection and fuses.
4. When the actuator is working heavily (i.e. due to snow/ice) the 4 A fuse is not to activate (thermal motor protection shall be activated priorly).
5. The actuator shall have a selector switch for following stated positions “Remote”/“Local”/“Off”.
   • “Off” – not possible with electrical manoeuvring
   • “Local” – local push button manoeuvring of the actuator, remote control manoeuvring not possible
   • “Remote” – Remote control of the actuator, local manoeuvring not possible
6. There shall be arranged a mechanical/electric interlock in a manor that electrical manoeuvring (local and remote) are not possible when the actuator is locked in manual operation.
7. When local manoeuvred, the actuator shall not be able to be operated (electrical) with push buttons in the cabinet to open or close the switchgear.
8. When remote control manoeuvred, the motor shall be operated by signal pulse trough cable (230 V A.C.)
9. The actuator shall be connected the RTU for remote control via seven conductors, two for 230 V A.C. supply, one for “actuator in”, one for “actuator out” and three for indication.
10. The actuator shall be prepared to be able to be connected via only six conductors, where three conductors are dedicated indication and three conductors are dedicated 230 V A.C. (“Actuator common”, “Actuator close” and “Actuator open”). There will not be continuous 230 V A.C. in both phases. This type of connection may only be made by single jumpers on the terminal strip.
11. For “Actuator close” and “Actuator open” energized conductor be equivalent with active manoeuvre. The duration of the control pulse is expected to be in the region of 1–2 seconds.
12. The motor should be contactor controlled, with locking circuit.
13. The actuator shall be delivered ready coupled, with terminal strip ready for pooled termination and available to measuring. Terminal strip should be the only interface towards RTU.
14. Actuator should contain attempt (e.g. burning resistance) to prevent that unacceptable high voltages could build up across the contactor windings.
15. There shall be built inn end position switches on the motor (in the local control circuit).
16. The actuator shall be equiped with a self regulating heating element (approximately 5 °C) of minimum 30 W. This is to prevent the forming of condense inside the actuator and should be permanently activated.
17. Components in the actuator shall be labeled with lasting and unique descriptions in accordance with the wiring diagram/circuit diagram. From the RTU for remote controlling the actuator should be able to be supplied with 230 V A.C. 1-phase and motor currents normally not exceeding 2.5 A.

4.2.2 Requirements to indicator

1. Indication shall be via three conductors, “Indication common”, “Indication close” and “Indication open”.
2. There should be minimum two potential free contacts to indication of both close and open position.
3. Potential free contacts to indication of close and open should be with closed position in the end positions. No (open/close) contacts should be closed with switch in mid-position (undefined).
4. The potential free contacts should at least work from 24 V A.C./D.C. to 230 V A.C. with operating currents (current load) in the range of 5–500 mA.
5. Position indication in the form of contactor towards RTU should at least fulfil the directives on reliable and secure indication.

4.2.3 Requirements to actuator, power supply

1. The actuator is powered by local electricity supplier, power technical house or station building.
2. The actuator shall be functioning on power supply: 230 V +10 %/-20 %, 1-phase, 50 Hz.
3. The actuator should at least be able to be used on both IT and TN power supply systems.

4.2.4 Actuator with UPS (additional/optional)

The actuator should be able to be equipped with optional power source that secures operation of the motor.

1. The actuator should maintain a capacity of minimum three operations at any time within eight hours of disappearance by normal power supply.

4.2.5 Requirements to actuator, mechanical

The following is to regard as minimum requirements to the actuator in the whole range of vertical movement together with draining function.

4.2.6 Requirements to actuator, mechanical design

1. The manual operation should be able to be secured with an ordinary padlock. It should also be an interlocking such that remote control can not find place when the operating mechanism is in the position of manual control.
2. The manual operations placement should be such that it can be operated in a normal upright working position.
3. Drainage-nipple shall be placed in the cabinet’s lowest point at the specified assembly such that any condensation water flows out.
4. Ventilation-nipple shall be mounted on top of the cabinet.
5. The actuator shall be built in a cabinet with a frontal hinged door.
6. The cabinet should be able to be locked with a padlock.
7. The switchgear position should be able to be controlled without opening of the front door. In other words the frontal hinged door should be equipped with an inspection window where the switchgear position can be controlled or an adequate solution.
8. The mechanical position indication locally in the actuator shall comply with applicable regulations regarding secure and reliable indication.
9. The bearings shall be maintenance-free.
10. No conductor should come into contact with any moving parts or too close to the heating element.
11. If lubricating grease should be used, it should be of a type that is anti-corrosive.
12. There shall be complete sealing between the output shaft and the cabinet’s upper part.
13. All electrical and mechanical parts should be easy to access to perform inspection, functional tests and maintenance when the hatch cover is removed.
14. For emergency operation the actuator shall be equipped for manual operation. This manual operation shall be lockable in three different positions:
    1. Remote control
    2. Manual operation CLOSE
    3. Manual operation OPEN

4.3 Documentation/tests to actuators 230 V A.C.

4.3.1 Documentation for actuators

Documents should be kept and filed by the manufacturer in a systematic way such that traceability between components and corresponding document is ensured. The manufacturer shall keep documents in a suitable place in ten years. Documentation shall be available to NNRA at enquiry.

1. It should at possible frame agreement (or as base by technical approval) be submitted with necessary documentation to evaluate the actuator technically.
2. Documents that shall be used in connection with NNRA’s execution of work shall be in Norwegian, beyond that English can be accepted.

4.3.2 Documents

The following documents shall be stored at the manufacturer and be delivered on request from NNRA:

1. Random based tests protocols (minimum for every 50th actuator)
2. Traceability protocols
3. Certificates of materials

The following documents shall be included in the tender:

1. Copy of samples on certificates of type tests
2. Suggestion to procedures for routine test-/final inspection protocol together with template for test protocols prepared by the manufacturer and to be approved by the NNRA
3. Suggestion on test procedures
4. Suggestion on SAT prepared by the manufacturer and to be approved by the NNRA
5. Actuator shall have an assembly manual in Norwegian and be well designed with illustrations
6. Copy of maintenance manual in Norwegian
7. Plan- and cross-section drawings of the actuator or data sheet/catalogue
8. Copy of list and necessary information of parts that possibly wears and must be replaced during the actuators lifespan
9. Copy of the check list in checklist in filled in state
10. Copy of other documents that are required in the specification

NB! If there are other relevant tests, standards or instructions etc. which are used and that not are mentioned in this specification, this shall be pointed out by the manufacturer.

The following documents shall follow each unit at deliverance before the deliverance are considered as complete:

1. Routine test- and final inspection protocol
2. SAT control in Norwegian
3. Assembly manual in Norwegian well designed with illustrations
4. Maintenance manual in Norwegian

4.3.3 Drawings

The following drawings are to be delivered NNRA at contracting frame agreement (or as base by technical approval):

1. Dimensional plan and cross-section drawing of actuator should be provided in paper based on .dwg files.
2. Complete bills of material with designation of type or possibly El.no.
3. Make detailed layout drawings with support of the NNRA adapted to NNRA’s poles where every component included actuating lever and possibly switchgear drawn in and uniquely marked with detail drawings and bills of materials.

4.3.4 Tests

1. The manufacturer should make proposals to test procedures possibly in accordance with [IEC 60694] and [IEC 60129] to be delivered with the tender.
2. Tests shall be performed in accordance with Norwegian or international standards/norms.
3. Arcing test shall be delivered upon NNRA’s request.
4. Control of vital measures, VZ μ-thickness measurement of hot dip galvanized components and material tests shall be preformed as random based tests. VZ μ-thickness measurement of hot dip galvanized components shall be performed accordingly to [NS-EN ISO 1461].
5. The test procedures shall be divided in three levels:
   • type tests
   • random test
   • final inspection/Routine test
6. Test protocols shall be delivered with both deliverances directly to NNRA’s storehouse and deliverances directly to site.

4.3.5 Spare parts

Estimation of necessary spare parts shall be stated by the manufacturer.

5 References

Testing and tolerances according adequate ICE publications.

6 Appendix

6.1 Attached drawings

7 Checklist

8 Old version in Norwegian