H7-Siemens 8WL5070-1

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02.09.2002
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10.02.03ws
Tension Wheel Assembly Sicat 8WL5070

for Tensioning Equipment in Overhead Contact Line Systems
Operating Instructions Version 1.1.5
8WL5070-1
8WL5070-0B
Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
Copyright © Siemens AG 2003 - 2009. All rights reserved.

The group Transportation Systems of the Siemens AG has established and
maintains for the scope
Project Planning, Aquisition, Engineering, Procurement, Production, Assembly,
Commissioning and Service of Products, Systems and Services in the fields of
Rail Automation, Electrification, Locomotives, Trains, Mass Transit, Bogies,
Turnkey Systems and Integrated Services
an integrated quality, safety, health and environmental management system in
conformity with the standards:
ISO 9001:2000
ISO 14001:2004
OHSAS 18001:1999
Certification was issued by the DNV Zertifizierung und Umweltgutachter GmbH
and confirmed by regular audits.
If you require additional copies of these operating instructions, please order from
the responsible Siemens sales office, stating the title and the following
document number:
A6Z08100028448
Issued by:
Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
P.O. Box 3240
91050 Erlangen
Germany
E-Mail: techcom.el.mobility@siemens.com
Subject to change without notice!
© Siemens AG 2003 - 2009
NOTE
The reproduction, transmission or use of this document or its contents is not permitted without
express written authority. Offenders will be liable for damages. All rights, including rights created
by patent grant or registration of a utility model or design, are reserved.
Sicat® is a registered trademark of Siemens. The other names appearing in this documentation
may be trade names, the use of which by third parties for their own purposes may infringe the
rights of the respective owners.
2 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

Table of contents
1 General ............................................ 5
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Description of the warning notices . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Sources of danger .................................... 9
3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2.1 Tension wheel assembly 8WL5070-0B . . . . . . . . . . . . . . . . . . . . . 11
4.2.2 Tension wheel assembly 8WL5070-1 . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Possible arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1 Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.1 Tension wheel assembly without cabling (standard) . . . . . . . . . . . 16
5.2.2 Tension wheel assembly with fitted wires (optional) . . . . . . . . . . . 16
5.3 Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Tools and working equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.2 Tightening torque for bolts and nuts (according to DIN VDE 0216) 17
6.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2.1 Calculations for rigging the tension wheel assembly . . . . . . . . . . 17
6.2.2 Winding wires to the tension wheel assembly . . . . . . . . . . . . . . . 30
Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 3 / 48

6.3 Fitting the tension wheel assembly to the fixing elements . . . . . . 34
6.3.1 Fitting the 8WL5070-0B tension wheel assembly to the fixing
elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.3.2 Fitting the 8WL5070-1 tension wheel assembly to the fixing
elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.4 Connecting the tension wheel assembly to weight set and catenary
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.4.1 Making the connection to the weight set . . . . . . . . . . . . . . . . . . . 36
6.4.2 Making the connection to the catenary system . . . . . . . . . . . . . . 37
6.5 Final function test and readjustment on the tension wheel
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5.1 Checking the rigging of the tension wheel assembly . . . . . . . . . . 38
6.5.2 Adjusting of the latching plate for type 8WL5070-0B and
8WL5070-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5.3 Adjusting the safety hoop for type 8WL5070-0B . . . . . . . . . . . . . 40
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1.1 Function test in the tension wheel assembly . . . . . . . . . . . . . . . . 42
7.2 Repairs following a fault in the overhead contact line ......... 42
7.2.1 Repairs following contact wire and/or catenary breakage . . . . . . 42
7.2.2 Repair following short-circuit with current flow through the tension
wheel equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1 Disassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2 Recycling and disposal ................................ 45
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1 General data ........................................ 46
9.2 Order numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Materials of individual parts of the tension wheel assembly .... 46
9.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
10 Abbreviations / definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

General
1 General
These operating instructions are valid for the standard version of the product
Sicat 8WL5070 as from model year 2003.
The operating instructions (according to IEC 62079:2001) are intended to make
any personnel familiar with the product.
WARNING
Death, serious physical injury and damage to property can occur.
Observe the warning notices in Section 2 "Safety" on page 6.
Observe the safety regulations and warnings included in these operating instructions and on the
product. Read these operating instructions completely before installing this product. Keep these
operating instructions ready to hand so that you can refer to important information at all times.
A correct and safe operation of the product can be guaranteed only after suitable transport, proper
storage, erec-tion, assembly, commissioning and careful maintenance.
NOTE
In the interests of clarity, these operating instructions do not contain all detailed information for all
types of the product and cannot take all conceivable conditions for the erection, operation and
maintenance into account.
If you require further information, or if special problems arise, that have not been referred to suffi-
ciently in the op-erating instructions, the necessary information can be requested through the local
Siemens branch office.
We also draw attention to the fact that the contents of these operating instructions do not represent
a part of an earlier or existing agreement, warranty or legal relationship, nor do they alter the such.
All obligations on behalf of Siemens are based upon the respective purchase contract, which also
contains the complete and exclusively applicable warranty conditions. These contractual warranty
conditions are neither ex-tended nor limited by the explanations given in these operating instruc-
tions.

Safety
2 Safety
2.1 Description of the warning notices

These operating instructions contain warnings based on signal words in order to
indicate the degrees of danger.
Such warning notices can also be utilised in the form of sign boards or as
stickers attached to the product.
Symbol SIGNAL WORD

Meaning...
Symbol Signal word Meaning
Danger in the context of these operating instructions and the warning

notices on the products themselves, means that death or serious
physical injury will occur, if the corresponding safety measures are
not obeyed.
Warning in the context of these operating instructions and the warning

notices on the products themselves, means that death or serious
physical injury can occur, if the corresponding safety measures are
not obeyed.
Attention in the context of these operating instructions and the warning

notices on the products themselves, means that a light physical
injury can occur, if the corresponding safety measures are not
obeyed.
Attention in the context of these operating instructions and the warning

notices on the products themselves, means that a damage to
property can occur, if the corresponding safety measures are not
obeyed.
Note in the context of these operating instructions is an important infor-

mation related to the product or to the respective section of the
documentation, to which special attention is to be drawn.

Safety
2.2 Intended use
WARNING
Use of the product for purposes that are not intended can cause death, serious physical injury,
considerable damage to property and environmental pollution.
Use the product only for its intended purpose (see also Section 3 "Purpose and
use" on page 10).
The use complies with the intended purpose if:
• the product is operated in accordance with the agreed terms of delivery and
the stated tech-nical specification, and
• any supplied devices and special tools are used exclusively for the intended
purpose and in accordance with the appropriate instructions in these oper-
ating instructions.
All other methods of use are forbidden unless explicit written agreement has
been issued by Siemens AG.
2.3 Personnel qualification

A person is qualified if he/she is familiarized with:
• the installation,
• the construction,
• the operation,
• the maintenance of the product and
• the associated dangers.
In addition, all persons performing the installation, commissioning, operation

and maintenance of the product must also possess qualifications and experi-
ence in the following basic skills:
• installation methods,
• working in accordance with, and on the basis of drawings,
• working in accordance with the operating instructions,
• accident prevention and safety regulations,
• commissioning methods and commissioning procedures,
• first aid.
Please refer to national regulations (e. g. BGV A 3 in Germany, EN 50110 in
Europe).

Safety
2.4 Safety requirements

Pay attention to the generally applicable and legally binding safety regulations.
Instruct the personnel regularly on the currently applicable rules and regulations,
the generally applicable accident prevention regulations and legally binding
safety instructions.
Irrespective of these, the following five safety rules according EN 50110-1 (12/
1996) apply:
NOTE
1. Isolate the plant
2. Secure against being switched on
3. Make sure there is no residual voltage in the plant
4. Earth and short-circuit the plant
5. Cover or safeguard live parts
Use personal protective equipment as specified by national accident prevention

regulations (in Germany BGV A 1 or BGR 189-199).

Safety
2.5 Sources of danger

If the specified requirements and conditions have not been obeyed or the safety
instruction have not been followed, then dangers are threatened by:
DANGER
Risk of fatal injury through high voltage at the electrical system.
Observe the warnings in these operating instructions and on the product.
DANGER
Risk of fatal injury through railway vehicles during work in track area.
Observe the regional applicable regulations and the instructions of the plant manufacturer and
operator.
DANGER
Risk of fatal injury through work in heights on working platforms, ladders and poles.
Observe the regional applicable regulations and the instructions of the plant manufacturer and
operator.
ATTENTION
Risk of injury through falling and/or toppling parts and risk of trapping through moving parts.
Observe the warnings in these operating instructions and on the product.

Purpose and use
3 Purpose and use

Tension wheel assemblies are part of tension wheel equipments in overhead
contact line systems. They are mounted at the end of a tension section. When
tension wheels are used for tensioning, the contact wire or catenary wire is
maintained at a constant tensile force, irrespective of variations in the wire or
cable lengths caused by temperature changes. This is necessary to maintain a
fault-free power transfer to the traction unit.
Tension wheel assemblies of the type 8WL5070 have a mechanical locking
system (latching device) which, in the case of a break in the contact wire or
catenary wire, prevents the weights used for applying tensile force from falling
onto the track, nearby pathways etc.. Subsequent damage to the overhead
contact wire system is prevented.
The type 8WL5070 tension wheel assemblies permit tensioning of movable
contact and/or catenary wires with a tensile force up to 40 kN.

Design
4 Design
4.1 General
There are two variants of the 8WL5070 tension wheel assembly (see table).
They differ in the constructions of the swing lever and suspension components.
Due to this constructions, the mounting in a tension section can be adapted opti-
mally to the conditions at the mounting location. The variant must already be
selected in the overhead contact line engineering stage. The type of tension
wheel assembly mounting determines the connection to the contact wire and/or
catenary wire and the arrangement of the tensioning weights.
Variant Operational conditions and mounting type
8WL5070-0B Open section, mounting on steel or concrete pole
8WL5070-1 Narrow installation conditions, mounting on HE poles, walls or
inside tunnels
NOTE
Use only steel wires 8WL7090-0 and 8WL7090-0C when rigging up the tension wheel assembly.
The special design enables these steel wires to withstand high alternating bending stress and to
provide a long service life.
4.2 Variants
4.2.1 Tension wheel assembly 8WL5070-0B
This tension wheel assembly can be mounted on steel or concrete poles. It has
a support bracket for a guide tube up to ø 43.5 mm and is suitable for weight sets
of 200 to 500 mm diameter. The cable for the weight sets is arranged on the side
of the tensioning wheel facing away from the pole. For the numbering of the indi-
vidual parts and the corresponding legend, see Figure "Tension wheel assembly
8WL5070-0B" on page 12. The guide tube bracket (5) has a safety hoop (23)
attached to it. This hoop prevents the weight wire from jumping from the rim over
the edge of the wheel body in the event of a sudden removal of the load of the
tension wheel assembly, e.g. in case of breakage of the contact wire/catenary
wire. The safety hoop (23) must be adjusted after the contact wire/catenary wire
to be tensioned has been connected to the tension wheel assembly (see Section
6.5 "Final function test and readjustment on the tension wheel assembly" on
page 38).

Design
389
320
3
498
7, 8, 9
200 - 500 1)
12
23 dimensions in mm
17a
1 wheel body 8 washer 13

2 swing lever 9 M12 hexagon nut
3 suspension 10 washer
4 latching plate 11 M24 hexagon nut
5 guide tube bracket 12 5x40 split pin
6 M24x600 pivot 17a wedge-type dead-end clamp with
special wedge *
7 M12x50 hexagon bolt 23 safety hoop
* not included in the scope of delivery

1) diameter of weights
Tension wheel assembly 8WL5070-0B

Design
4.2.2 Tension wheel assembly 8WL5070-1
This tension wheel assembly is suitable for narrow installation conditions and
can be attached to HE poles, buildings or tunnel walls. The cable for the weight
sets is arranged on the side of the tensioning wheel body facing towards the pole
or wall. This variant is suitable for weight sets of a diameter up to 410 mm and
for rectangular weights. For the numbering of the individual parts and the corre-
sponding legend, see Figure "Tension wheel assembly 8WL5070-1" on page 13.
384
1
75
16
470
498
7, 8, 9
10, 11
225
451
12
dimensions in mm
17a
1 wheel body 8 washer 13

2 swing lever 9 M12 hexagon nut
3 suspension 10 washer
4 latching plate 11 M24 hexagon nut
5 guide tube bracket 12 5x40 split pin
6 M24x600 pivot 16 securing element (on both sides)
7 M12x50 hexagon bolt 17a wedge-type dead-end clamp with
special wedge *
Tension wheel assembly 8WL5070-1

Design
4.3 Possible arrangements

Tensioning equipment with tension wheel assemblies are suitable for common
as well as for separate tensioning of contact wires and/or catenary wires. The
following arrangements on the pole or wall are possible:
• individual
• parallel • above each other, offset
≥ 590
dimension in mm
a
a
a horizontal distance between pivot axes ≥ 350 mm, or diameter of weights + 150 mm

Design
• one in front of the other
8WL5070-1

dimension in mm
8WL5070-0B

dimension in mm
b horizontal distance between pivot axes ≥ 350 mm, or diameter of weights + 150 mm
NOTE
The minimum horizontal distance apply for the use of Siemens-supplied weights.
When using weights up to 300 mm diameter, the minimum horizontal distance between the weight
column or rotary bolt axes of the tension wheel suspension can be reduced to 350 mm.

Transport and storage
5 Transport and storage
5.1 Transport conditions

The transportation equipment to and at site must be of the correct type and have
the required load capacity for the equipment to be lifted. Note the weight infor-
mation, centre of gravity, lifting and transportation instructions on the packing.
5.2 Packing
5.2.1 Tension wheel assembly without cabling (standard)
The tension wheel assemblies are delivered in suitable packaging, for example
in skeleton container pallets or on Euro pallets. To prevent contact between the
tension wheel assemblies and damage of the zinc surface through transport
vibrations, cardboard or chip cushions (shrink- wrapped) are placed between
the assemblies.
NOTE
When you intend to transport the completely assembled tension wheels elsewhere, put them verti-
cally into crate pallets without intermediate excelsior layers respectively intermediate layers which
could stick to grease and bitumen
5.2.2 Tension wheel assembly with fitted wires (optional)
The wires attached to the wheel body must be fixed firmly to the wheel body with
wire or adhesive tape for transportation.
5.3 Checks on receipt

On receipt of the delivery, check all items for damage and compare it with the
delivery note to make sure that the delivery is complete.
NOTE
If any received parts are damaged, immediately identify and record its severity and cause and
inform the manufacturer. In case of transportation damage, also inform the shipping company.
Replacements cannot be supplied without a written record of the damage.
5.4 Storage
Protect the tension wheel assembly and, if applicable, the wires from dust and
heavy fouling.

Installation
6 Installation
NOTE
The guide and the weight set are not included in the scope of delivery.
6.1 Tools and working equipment

6.1.1 Tools
• abrasive cutter
• tie wire, adhesive tape or similar fixing material
• spirit level
• rubber mallet
• vice
• two ring and open-end spanners or ratchet spanner, size 19 and 36, for
each worker
• torque spanner for size 19 (torque range 10 - 200 Nm)
• thermometer
• folding rule
• tape measure at least 10 m long
6.1.2 Tightening torque for bolts and nuts (according to DIN VDE 0216)
Bolts Tightening torque
M12-A2-70 hexagon bolt 56 Nm
6.2 Preparation
NOTE
Please refer Section 9 "Technical data" on page 46 and Section 10 "Abbreviations / definitions" on
page 47.
6.2.1 Calculations for rigging the tension wheel assembly
Perform the calculations described in this section in preparation for rigging the
corresponding type of tension wheel assembly.
The calculations described are intended to serve as examples of how to rig up
an individually arranged tension wheel assembly. If an arrangement involves
multiple tension wheel assemblies, please also bear in mind the respective refe-
rence dimensions.

Installation 8WL5070-0B
6.2.1.1 Tension wheel assembly 8WL5070-0B

s
a var
eu
h
L GS
L GF
avar distance between eye of support bar and tension wire

eu vertical mounting distance between lower hook bolt axis and tension wire
G upper surface of terrain
h minimum distance above terrain
LGF length of weight guiding tube
LGS length of support bar
s distance between outer edge of wheel rim and pulley axis in centre position (see Section
"Preparing an adjustment graphic" on page 19)
Dimensions of tension wheel assembly 8WL5070-0B
Variation of length ΔL of contact and catenary wires
Formula ΔL = lmax * α * ΔT [m]
lmax maximum half of span length

α coefficient of variation of length of contact and catenary wires to be tensioned
ΔT temperature range of wire of contact and catenary wires to be tensioned
Minimum distance h of tension wire above terrain
Formula h = 3 * ΔL + LGS + 0.50 [m]
ΔL variation of length of contact and catenary wires


8WL5070-0B Installation
Cutting length LGF of weight guiding tube
Formula LGF = 3 * ΔL + LGS /2 + 0.7 [m]

NOTE
The value calculated for LGF represents a minimum value. If necessary, a longer weight guiding
tube can be selected.
Vertical distance eu of lower hook bolt axis from tension wire
Formula eu = LGF + 0.30 [m]
LGF cutting length of weight guiding tube
Connecting the tension wheel assembly to the catenary system (wire on

the wheel hub)
NOTE
Use only steel wire 8WL7090-0C when rigging up the wheel hub of the tension wheel assembly
8WL5070-0B.
The steel wire 8WL7090-0C has a specified length. The length between the
thimbles is 7.50 m.
Connecting the tension wheel assembly to the weight set (wire on the
wheel rim)
NOTE
Use only steel wire 8WL7090-0 when rigging up the wheel rim of the tension wheel assembly
8WL5070-0B.
Cutting length LR
Formula LR = 1.5 * ΔL + 3.62 [m]
LR Length of wire on the wheel rim for connection to the weight set
Preparing an An adjustment graphic is used to show the operating range of the tensioning
adjustment graphic equipment (tension wheel assembly).

The steel wire lengths and the number of wire turns on the wheel body (wheel
hub and wheel rim) can be determined theoretically according to the tempera-
ture and the span lengths and compared with the actual condition. The graphic
is therefore an important instrument for adjusting the weight set during installa-
tion and for checking the rigging of the tension wheel assembly and the position
of the weight sets after installation.
NOTE
The graphics can be designed under the given operating conditions with the help of the formulae
below. (see Section "Example for an adjustment graphic" on page 22).
The tension wheel assembly can compensate a maximum variation of length of

1.43 m in the contact and catenary wires to be tensioned. The wire turns on the
wheel hub and the wheel rim are counted starting at the spoke with wire casing.
At the lowest wire temperature, at least 2/5 wire turns (the distance of 2 spokes)
have to be on the wheel hub. At the highest wire temperature, at least 2/5 wire
turns (the distance of 2 spokes) have to be on the wheel rim. For the tension
wheel assembly, this means that the following number of wire turns are on the
wheel hub and the wheel rim in centre position:
WTM 2.17 wire turns on the wheel hub (drum) in centre position
WRM 1.92 wire turns on the wheel rim in centre position
NOTE
The centre position of the tension wheel assembly is constant for all adjustment graphics. The
winding length of the wire is 0.470 m for one turn on the wheel hub (drum) and 1.412 m on the
wheel rim.
Temperature TM in centre position
Formula TM = Tmin + ΔT/2 = Tmax - ΔT/2 [°C]
TM temperature in centre position of the wheel body

Tmin lowest temperature
Tmax highest temperature
ΔT temperature range of contact and catenary wires to be tensioned
Distance aM between eye of support bar and tension wire in centre position
Formula aM = lmax * α * 1,5 * ΔT + a [m]

a distance between eye of support bar and tension wire at lowest temperature and
and maximum span length
lmax maximum half span length

The minimum distance amin between the eye of the support bar and the tension
wire at lowest temperature and at maximum span length must be 0.380 m. The
distance a from the eye of the support bar to the tension wire at lowest temper-
ature and at maximum span length must be selected greater than amin.
When doing so, bear in mind not only the available mounting space but also the
possible mounting tolerances for adjustment of the weight set. A distance a of
0.50 m is recommended for tension wheel assembly 8WL5070-0B.
Distance avar between eye of support bar and tension wire
Formula avar = aM - lvar * α * 3 * (TM - Tvar)
aM distance between eye of support bar and tension wire in centre position
lvar variable half span length
Tvar variable temperature of contact and catenary wires to be tensioned
Number of wire turns WT var on the wheel hub (drum)
NOTE
Start to count the wire turns directly at the spoke with wire casing.
Formula WT var = WTM - lvar * α * (TM - Tvar) / 0.47
WTM number of wire turns on the wheel hub in centre position

a coefficient of variation of length of contact and catenary wires to be tensioned
Number of wire turns WR var on the wheel rim
NOTE
Formula WR var = WRM - lvar * α * 3 (TM - Tvar) / 1.412
WRM number of wire turns on the wheel rim in centre position


Example for an This section shows an example of how to prepare an adjustment graphic. The
adjustment graphic following tables list the assumed parameters and the calculated values for the
example. The adjustment graphic is shown in Figure "Adjustment graphic for
8WL5070-0B tension wheel assembly" on page 23.
Assumed parameters (example):
Parameter Value Explanation
a 0.50 m Distance between eye of support bar and tension wire at lowest
temperature and maximum span length
Taken into account:
• mounting space available
• mounting tolerances when adjusting weight set
s 2.29 m Distance between outer edge of wheel rim and pulley axis in centre
position
α 1.73*10-5 K-1 Coefficient of variation of length of contact and catenary wires to be
tensioned
(copper)
lmax 700 m Maximum half of span length
lvar 550 m Variable half of span length
ΔT 110 K Temperature range of contact and catenary wires to be tensioned
Tmax 80°C Maximum temperature
Tmin -30°C Minimum temperature
Tvar 20°C Variable temperature of contact and catenary wires to be tensioned
WTM 2.17 Number of wire turns on the wheel hub in centre position
WRM 1.92 Number of wire turns on the wheel rim in centre position
LGS 1.20 m Length of support bar
Calculated values for the adjustment graphic:

h 5.69 m Minimum distance above terrain
LGF 5.29 m Cutting length of weight guiding tube
ΔL 1.33 m Variation of length of contact and catenary wires
eu 5.59 m Vertical distance of hook bolt axis from tension wire
LR 5.62 m Cutting length of tension wheel wire on the wheel rim for connec-
tion to the weight set
TM 25 °C Temperature in centre position
aM 2.50 m Distance between eye of support bar and tension wire in centre
position
avar 2.36 m Distance between eye of support bar and tension wire at 20°C
WT var 2.07 Number of wire turns on the wheel hub at 20°C
WR var 2.02 Number of wire turns on the wheel rim at 20°C
To prepare the adjustment graphic, perform the calculation for the minimum and
for the maximum half span length. The graphic of the wire turns is only based on
the maximum half span length.

s = 2.29 m
Wire turns
on the wheel hub on the wheel rim
(drum)
0.5 m
a
avar [m] [°C] WT var WR var
- 30°C - 30°
0.50 0.75 3.33
0.70 - 25°
- 20° 1.01 3.08

0.90
- 15°
1.10
- 10° 1.27 2.82
1.30
- 5°
1.50
0° 1.53 2.56
1.70
5°
1.90 10° 1.78 2.31
2.10 15°
2.30 20° example 2.04 2.05

2.36 2,07 2,02
+25°C centre position
2.50 25° 2.17 1.92
2.70 30° 2.30 1.79
2.90 35°
40° 2.56 1.53

3.10
45°
3.30
50° 2.81 1.28
3.50
55°
3.70
60° 3.07 1.02
3.90
65°
4.10 0.76
70° 3.33
4.30 75°
+80°C 3.59 0.51
4.50 80°
200 300 400 500 600 700
550
lvar [m]
upper surface of terrain
Adjustment graphic for 8WL5070-0B tension wheel assembly

Installation 8WL5070-1
6.2.1.2 Tension wheel assembly 8WL5070-1

s
eo
a var
eu
h
L GS
L GF
avar distance between eye of support bar and tension wire

eo vertical mounting distance between upper hook bolt axis and tension wire
eu vertical mounting distance between lower hook bolt axis and tension wire
G upper surface of terrain
h minimum distance above terrain
LGF length of weight guiding tube
s distance between outer edge of wheel rim and pulley axis in centre position (see Section
"Preparing an adjustment graphic" on page 26)
Dimensions of tension wheel assembly 8WL5070-1
Variation of length ΔL of contact and catenary wires
Formula ΔL = lmax * α * ΔT [m]
lmax maximum half of span length

Minimum distance h of tension wire above terrain
Formula h = 3 * ΔL + LGS + 0.70 [m]


8WL5070-1 Installation
Cutting length LGF of weight guiding tube
Formula LGF = 3 * ΔL + LGS /2 + 0.5 [m]

NOTE
The value calculated for LGF represents a minimum value. If necessary, a longer weight guiding
tube can be selected.
Vertical distance e of hook bolt axis from tension wire
Formula eo = 0.80 [m]
eo vertical distance of upper hook bolt axis from tension wire
Formula eu = LGF + 0.83 [m]
eu vertical distance of lower hook bolt axis from tension wire

LGF cutting length of weight guiding tube
Connecting the tension wheel assembly to the catenary system (wire on

the wheel hub)
NOTE
Use only steel wire 8WL7090-0C when rigging up the wheel hub of the tension wheel assembly
8WL5070-1.
The steel wire 8WL7090-0C has a specified length. The length between the
thimbles is 7.50 m.
Connecting the tension wheel assembly to the weight set (wire on the
wheel rim)
NOTE
Use only steel wires 8WL7090-0 when rigging up the tension wheel assembly 8WL5070-1 on the
wheel rim.
Cutting length LR
Formula LR = 1.5 * ΔL + 4.17 [m]
LR length of tension wheel wire on the wheel rim


Preparing an
adjustment graphic
NOTE
The graphics can be designed under the given operating conditions with the help of the formulae
below (see Section "Example for an adjustment graphic" on page 28).
An adjustment graphic is used to show the operating range of the tensioning

equipment (tension wheel assembly). The steel wire lengths and the number of
wire turns on the wheel body (wheel hub and wheel rim) can be determined
theoretically according to the temperature and the span lengths and compared
with the actual condition. The graphic is therefore an important instrument for
adjusting the weight set during installation and for checking the rigging of the
tension wheel assembly and the position of the weight set after installation.
The tension wheel assembly can compensate a maximum variation of length of
1.43 m in the contact and catenary wires to be tensioned. The wire turns on the
wheel hub and the wheel rim are counted starting at the spoke with wire casing.
At the lowest wire temperature, at least 2/5 wire turns (the distance of 2 spokes)
have to be on the wheel hub. At the highest wire temperature, at least 2/5 wire
turns (the distance of 2 spokes) have to be on the wheel rim. For the tension
wheel assembly, this means that the following number of wire turns are on the
wheel hub and the wheel rim in centre position:
WTM 1.92 wire turns on the wheel hub (drum) in centre position
WRM 2.17 wire turns on the wheel rim in centre position
NOTE
The centre position of the tension wheel assembly is constant for all adjustment graphics. The
winding length of the wire is 0.470 m for one turn on the wheel hub (drum) and 1.412 m on the
wheel rim.
Temperature TM in centre position
Formula TM = Tmin + ΔT/2 = Tmax - ΔT/2 [°C]

Tmin lowest temperature
Tmax highest temperature
Distance aM between eye of support bar and tension wire in centre position
Formula aM = lmax * α * 1.5 * ΔT + a [m]

a distance between eye of support bar and tension wire at lowest temperature and
and maximum span length
lmax maximum half span length

The minimum distance amin between the eye of the support bar and the tension
wire at lowest temperature and at maximum span length must be 0.60 m. The
distance a from the eye of the support bar to the tension wire at lowest temper-
ature and at maximum span length must be selected greater than amin.
When doing so, bear in mind not only the available mounting space but also the
possible mounting tolerances for adjustment of the weight set. A distance a of
0.70 m is recommended for tension wheel assembly 8WL5070-1.
Distance avar between eye of support bar and tension wire
Formula avar = aM - lvar * α * 3 * (TM - Tvar)
aM distance between eye of support bar and tension wire in centre position
Number of wire turns WT var on the wheel hub (drum)
NOTE
Formula WT var = WTM - lvar * α * (TM - Tvar) / 0.47
WTM number of wire turns on the wheel hub in centre position

Number of wire turns WR var on the wheel rim
NOTE
Formula WR var = WRM + lvar * α * 3 (TM - Tvar) / 1.412
WRM number of wire turns on the wheel rim in centre position


Example for an This section shows an example of how to prepare an adjustment graphic. The
adjustment graphic following tables list the assumed parameters and the calculated values for the
example. The adjustment graphic is shown in Figure "Adjustment graphic for
8WL5070-1 tension wheel assembly" on page 29.
Assumed parameters (example):
a 0.70 m Distance between eye of support bar and tension wire at lowest
temperature and maximum span length
Taken into account:
s 2.41 m Distance between outer edge of wheel rim and pulley axis in centre
position
α 1.73*10-5 K-1 Coefficient of variation of length of contact and catenary wires to be
tensioned
(copper)
lmax 700 m Maximum half of span length
lvar 550 m Variable half of span length
ΔT 110 K Temperature range of contact and catenary wires to be tensioned
Tmax 80°C Maximum temperature
Tmin -30°C Minimum temperature
Tvar 20°C Variable temperature of contact and catenary wires to be tensioned
WTM 1.92 Number of wire turns on the wheel hub in centre position
WRM 2.17 Number of wire turns on the wheel rim in centre position
LGS 1.20 m Length of support bar
Calculated values for the adjustment graphic:

h 5.89 m Minimum distance above terrain
LGF 5.09 m Cutting length of weight guiding tube
ΔL 1.33 m Variation of length of contact and catenary wires
eo 0.80 m Vertical distance of upper hook bolt axis from tension wire
eu 5.92 m Vertical distance of lower hook bolt axis from tension wire
LR 6.17 m Cutting length of tension wheel wire on the wheel rim
TM 25 °C Temperature in centre position
aM 2.70 m Distance between eye of support bar and tension wire in centre
position
avar 2.56 m Distance between eye of support bar and tension wire at 20°C
WT var 1.82 Number of wire turns on the wheel hub at 20°C
WR var 2.27 Number of wire turns on the wheel rim at 20°C
To prepare the adjustment graphic, perform the calculation for the minimum and
for the maximum half span length. The graphic of the wire turns is only based on
the maximum half span length.

s = 2.41 m
Wire turns
on the wheel hub on the wheel rim
0.7 m
(drum)
a
avar [m] [°C] WT var WR var
- 30°C 0.70 - 30° 0.50 3.58
0.90 - 25°
- 20° 0.76 3.33

1.10
- 15°
1.30
- 10° 1.02 3.07
1.50
- 5°
1.70
0° 1.28 2.81
1.90
5°
2.10 10° 1.53 2.56
2.30 15°
2.50 20° example 1.79 2.30

2.56 1.82 2.27
+ 25°C centre position 2.70 25° 1.92 2.17
2.90 30° 2.05 2.04
3.10 35°
40° 2.31 1.78

3.30
45°
3.50
50° 2.56 1.53
3.70
55°
3.90
60° 2.82 1.27
4.10
65°
4.30
70° 3.08 1.01
4.50 75°
+ 80°C 4.70 80° 3.34 0.76
200 300 400 500 600 700
550
lvar [m]
upper surface of terrain
Adjustment graphic for 8WL5070-1 tension wheel assembly

Installation
6.2.2 Winding wires to the tension wheel assembly
NOTE
These instructions apply only to tension wheel assemblies supplied without the wires fitted.
F
A
B
2
D
E
1 wheel body
2 swing lever
A wire casing
B slot
C wheel hub (drum)
D wheel axis
E for variant 8WL5070-0B:
direction of rotation for winding wire onto the wheel hub (small diameter)
F for variant 8WL5070-0B:
direction of rotation for winding wire onto the wheel rim (large diameter)
Wheel body details
NOTE
For variant 8WL5070-1, wind the wires in the opposite direction (E and F).

Installation
17 18 19 22
17 8WL7090-0 steel wire

18 8WL7090-0C steel wire with connecting fittings (7.5 m)
19 8WL1018-0 two-pin clevis link
22 8WL5167-5 guy clevis with pulley
Arrangement of wires on the wheel body
6.2.2.1 Winding wire to the wheel rim (weight suspension wire)
NOTE
Use only steel wire 8WL7090-0 when rigging up the tension wheel assembly.The special
design enables this steel wire to withstand high alternating bending stress and provides a long
service life. The steel wire, the one-hole wedge 8WL1201-0, the wedge-type dead-end clamp
8WL1180-7 and the special wedge 8WL1202-3 must be ordered separately.
Please refer the Figure "Wheel body details" on page 30 for the following work
steps.
1. Measure the projected length of the wire and mark the splitting point.
2. Wind adhesive tape or tie wire around the wire to both sides of the location
of the cut in order to prevent the steel wire from splaying. The layer of
adhesive tape or tie wire must be thin enough to allow the steel wire to be
inserted into the wire casing (A) on the wheel body.
3. Cut the wire (17) with an abrasive cutter.
4. Secure the swing lever (2) in a vice, making sure that the wheel body can
rotate freely in the swing lever.
5. Feed one end of the steel wire through the large opening in the wheel body
diameter and into the small opening of the wire casing (detail A).
6. Pull this end of the wire through and, behind the wire casing, form it into a
loop of about 15 cm length.
7. Insert the one-hole wedge into this loop so that its largest radius is positi-
oned in the loop.
8. Feed the loop with the one-hole wedge into the wire casing and tighten the
loop with the wedge with a firm tug. Secure the wedge by hitting it with a
rubber mallet.

Installation
9. Coil the wire up away from the wire casing (direction of rotation F) tightly
under tension up to middle position. Fix this position of the wire and secure
it against unwinding.
10. Coil the rest of the steel wire together in loops and fasten them to the
tension wheel assembly.
11. Take the wedge-type dead-end clamp (17a) and pull the end of the wire
through about 15 cm.
12. Form this end of the wire into a loop and pull it back through the dead-end
clamp.
13. Hold the special wedge in the loop and press the dead-end clamp over the
loop.
14. Pull the end of the wire tight. Secure the special wedge by hitting it lightly
with a rubber mallet.

Installation
6.2.2.2 Winding wire to the wheel hub (catenary connection)
NOTE
Use only steel wire 8WL7090-0C when rigging up the tension wheel assembly. The special
design enables this steel wire to withstand high alternating bending stress and provides a long
service life. The steel wire, the two-pin clevis link 8WL1018-0 and the guy clevis with pulley
8WL5167-5 must be ordered separately.
Please refer the Figure "Wheel body details" on page 30 for the following work
steps.
1. Take the steel wire (18) and mark it about 50 cm from its centre.
2. Lay the wire out flat and remove any twists in the wire.
3. Feed one end of the wire into the space between the wheel spokes contai-
ning a slot (detail B). Pull the wire through up to the mark, place it into the
slot at that point and secure it to the spoke, e.g. with wire.
4. Place the ends of the wire into the grooves in the left and right wheel hubs
(detail C). Wind the wire onto the wheel hub in parallel from inside to
outside.
5. Tension the wire, rotate the wheel body in direction E and coil the wire up to
middle position. Fix this position of the wire and secure it against unwinding.
6. Coil the rest of the steel wire together in loops and fasten them to the
tension wheel assembly
7. Take the guy clevis with pulley (22) and pull the split pin out of the pin of the
pulley.
8. Pull the pin out and take the pulley out of the clevis.
9. Place the longer section of wire over the circumference of the pulley.
10. Position the pulley complete with wire in the clevis and pull the pin through
the pulley.
11. Secure the connection to the split pin.
12. Take the two-pin clevis link (19) and remove on one side the split pin and a
strap.
13. Connect with the two-pin clevis link the ends of the wire (18), which are
fitted with thimbles.
14. Secure the connection to the pins with split pins.
15. Secure the guy clevis on the wheel body with wire.
16. Remove the wire used to secure the steel wire in work step 3 from the
spoke.

Installation
6.3 Fitting the tension wheel assembly to the fixing elements
NOTE
The fixing elements are not included as standard and must be ordered separately if required.
Note the requirements for the tension wheel assembly fixing elements:
• The holes in the upper and lower fixing element must be aligned to ensure
that the pivot (6) of the suspension is mounted in a vertical position.
A setting strap in the lower fixing element permits easy adjustment.
• The total material thickness of all fixing elements must not be more than
48 mm.
• The distance between the inside edges of the fixing elements must not be
more than 502 mm.
• The required edge width for the hole in the fixing element for the pivot must
be calculated statically and documented for verification.
For the mounting clearances, see Figures "Fixing elements and mounting clea-
rances at 8WL5070-0B" on page 34 and "Fixing elements and mounting clea-
rances at 8WL5070-1" on page 35.
6.3.1 Fitting the 8WL5070-0B tension wheel assembly to the fixing elements
3, 3a
500 +2
262
10, 11
dimensions in mm
1 wheel body 10, 11 washer, M24 hexagon nut

2 swing lever 12 5x40 split pin
3, 3a suspension, suspension tube 20 upper fixing element
4 latching plate 21 lower fixing element
6 M24x600 pivot
View Y see Section 6.5.3
Fixing elements and mounting clearances at 8WL5070-0B

Installation
1. Pull the split pin (12) out of the pivot (6), unscrew the hexagon nut (11) and
pull the pivot out of the suspension tube (3a).
2. Push the suspension (3) between the fixing elements (20, 21) so that the
suspension tube (3a) is flush with the holes in the two fixing elements.
3. Push the pivot (6) through the upper fixing element (20), the suspension
tube (3a) and the lower fixing element (21).
4. Push the washer (10) onto the pivot (6), screw the hexagon nut (11) onto
the pivot and slightly tighten it.
5. Secure the nut with the split pin (12).
6. Hang the swing lever (2) with the wheel body into the suspension bracket.
The wheel body must be aligned vertically and rest with its teeth in the latching
plate (4). Adjust the wheel body by means of the pivot and setting strap provided
on the fixing element. Place a spirit level on the outer face of the wheel body and
check that the wheel is vertical.
6.3.2 Fitting the 8WL5070-1 tension wheel assembly to the fixing elements
16
6
20
21
dimensions in mm
12
1 wheel body 10, 11 washer, M24 hexagon nut

2 swing lever 12 5x40 split pin
3, 3a suspension, suspension tube 16 securing element (on both sides)
4 latching plate 20 upper fixing element
6 M24x600 pivot 21 lower fixing element
Fixing elements and mounting clearances at 8WL5070-1

Installation
1. Pull the split pin (12) out of the pivot (6), unscrew the hexagon nut (11) and
pull the pivot out of the suspension tube (3a).
2. Push the suspension (3) between the fixing elements (20, 21) so that the
suspension tube is flush with the holes in the two fixing elements.
3. Push the pivot (6) through the upper fixing element (20), the suspension
tube (3a) and the lower fixing element (21).
4. Push the washer (10) onto the pivot (6), screw the hexagon nut (11) onto
the pivot and slightly tighten it.
5. Secure the nut with the split pin (12).
6. Unscrew and remove the two securing elements (16) from the swing
lever (2).
7. Hang the swing lever (2) with the wheel body into the suspension bracket.
8. Refit the securing elements (16).
The wheel body must be aligned vertically and rest with its teeth in the latching
plate (4). Adjust the wheel body by means of the pivot and setting strap provided
on the fixing element. Place a spirit level on the outer face of the wheel body and
check that the wheel is vertical.
6.4 Connecting the tension wheel assembly to weight set and catenary system
6.4.1 Making the connection to the weight set
The following conditions must be provided by others on site in accordance with

the engineering:
• the weight guide tube is already mounted on the pole and the tension wheel
assembly
• the weight set is complete
• the length of the weight wire from the middle of the tension wheel assembly
to the connecting point on the wedge-type dead-end clamp is determined
according to Section 6.2.1 "Calculations for rigging the tension wheel
assembly" on page 17.
• the tension wheel assembly is aligned in its centre position and the excess
steel wire (i.e. rest of the steel wire not coiled up) is rolled out.
• the latching plate is concentrically aligned with the wheel body and firmly
secured and the wheel body is firmly secured on the latching plate.
Proceed as follows:
1. Check once again the wire turns on the wheel rim and on the wheel hub.
2. Measure the length of the unrolled weight wire from the tension wire to the
connecting point of the eye of the support bar according to Section 6.2.1
"Calculations for rigging the tension wheel assembly" on page 17.
3. Turn the tension wheel assembly until the wedge-type dead-end
clamp (17a) on the weight wire is at the required height.

Installation
NOTE
In it is found in the course of the installation work performed up to this point that the rigging of the
tension wheel assembly is incorrect, there is a possibility to correct the clamping point on the
weight wire by undoing the wedge-type dead-end clamp (17a).
4. Remove the wedge-type dead-end clamp (17a) on the weight wire if the
length of the wire has to be adjusted.
5. When the position of the wedge-type dead-end clamp on the weight wire
corresponds to the specified level of connection, hit the special wedge hard
to drive it into the wedge-type dead-end clamp.
6. Using a suitable lifting device, lift the complete weight set up to the level of
the wedge-type dead-end clamp.
NOTE
When connecting the weight wire to the support bar, make sure that the weight wire is not twisted.
7. Bolt the support bar firmly to the wedge-type dead-end clamp.

8. Secure the bolted connection by inserting a split pin in the pin.
9. Lower the weight set with lifting device.
6.4.2 Making the connection to the catenary system
NOTE
The tension wheel assembly is to be connected to the catenary system in accordance with
the details of each specific project; only an example is described here.
All connecting parts must be suitable for the permissible operating forces in the catenary system
and must be provided on site.
18 22 29 28 29 27 29 30
18 8WL7090-1C steel wire with connecting fittings 28 catenary/contact wire 1.5 m

22 guy clevis with pulley 29 dead-end clamp
27 insulator 30 catenary/contact wire (catenary)
Connection to the catenary system (for example)
1. Cut an approx. 1.5 m long section of catenary wire or contact wire (28)
according to the cross-section of the catenary wire or contact wire to be
tensioned and fit the dead-end clamps (29) on the ends of the catenary or
contact wire as connecting parts.

Installation
2. Insert the thus prepared section of catenary wire/contact wire with the
connecting part into the guy clevis (22).
NOTE
Observe the permissible operating force for catenary or contact wire stringing grips and the ratchet
puller.
3. Fit a catenary or contact wire stringing grip to catenary or contact wire (28).
4. Bearing in mind the maximum length of the ratchet puller, fit a second strin-
ging grip to the catenary or contact wire (30) to be tensioned.
5. Hook a sling into each contact wire/wire stringing grip.
6. Pull the ratchet puller out to its maximum length and suspend the ratchet
puller in the catenary or contact wire stringing grips.
7. Tension the ratchet puller until the wheel body lifts out of the latching
plate (4).
8. Adjust the height of the weights according to the individual project specifi-
cations.
9. Move the dead-end clamp on the catenary wire/contact wire to be tensioned
until the connection can be established at the end of the 1.5 m long piece of
wire/contact wire (28), including insulator (27).
10. Check all connections.
11. Slacken the ratchet puller.
12. Remove the ratchet puller.
13. Remove the catenary or contact wire stringing grips and slings.
6.5 Final function test and readjustment on the tension wheel assembly
6.5.1 Checking the rigging of the tension wheel assembly
Visually inspect the rigging of the tension wheel assembly on the basis of the
prepared adjustment graphic. In doing so, compare the calculated values for the
number of wire turns on the wheel rim and on the wheel hub with the actual
condition on the wheel body. Any deviations found are an indication of errors
which may have made during the rigging operation.
6.5.2 Adjusting of the latching plate for type 8WL5070-0B and 8WL5070-1
After the wire ropes and wires, that are to be tensioned, have been fitted and the
tension wheel assembly has finally been positioned relative to the track, the
distance between latching plate (4) and wheel body (1) has to be adjusted (see
Figures "Adjusting the distance between latching plate and wheel body for
8WL5070-0B" on page 39 and "Adjusting the distance between latching plate and
wheel body for 8WL5070-1" on page 40).

Installation
1. Check the distance between latching plate (4) and wheel body (1). The
distance between these components must be 48 mm. Readjust the latching
plate if this distance is not as specified.
2. Loosen the four bolted connections (7, 8, 9) if necessary, to be able to move
the latching plate (4).
3. Put a distance piece (26) from approx. 3 mm of thickness (e.g. folding rule)
on the latching plate. Push the latching plate to the wheel body (1) and
centre the latching plate to the rim.
4. Tighten the four bolted connections M12 (7, 8, 9) to a tightening torque of
56 Nm.
5. Remove the distance piece (26) and check the distance 48 mm.
view X
1
48
45
26
7, 8, 9
dimensions in mm
X
1 wheel body
4 latching plate
7, 8, 9 M12x50 hexagon bolt, washer, M12 hexagon nut
26 distance piece*
Adjusting the distance between latching plate and wheel body for 8WL5070-0B

Installation
view X
1
48
45
26
4
7, 8, 9
dimensions in mm
X
1 wheel body
4 latching plate
7, 8, 9 M12x50 hexagon bolt, washer, M12 hexagon nut
26 distance piece*
Adjusting the distance between latching plate and wheel body for 8WL5070-1
6.5.3 Adjusting the safety hoop for type 8WL5070-0B
Check the position of the safety hoop (23) to the weight wire (17).
The weight wire runs inside the safety hoop (see Figure "Safety hoop for the
guidance of the weight wire" on page 40). The distance to the safety hoop shall be
approx. 3 mm to the front and to the side (see Figure "Distances between weight
wire and safety hoop in the view Y*" on page 41).
23
5
24 17
25
5 guide tube bracket

17 weight wire
23 safety hoop
24 plate
25 M10 hexagon nut
Safety hoop for the guidance of the weight wire

Installation
dimensions in mm
1 wheel body
17 weight wire
23 safety hoop
* see Figure "Fixing elements and mounting clearances at 8WL5070-0B" on page 34

Distances between weight wire and safety hoop in the view Y*
NOTE
The safety hoop (23) is supplied firmly mounted to the guide tube bracket (5).
Adjust the safety hoop as follows:

1. Loosen one hexagon nut (25) per bolted connection on the plate (24) until
the safety hoop (23) can be moved in the long holes.
2. Set the distances to 3 mm between the weight wire (17) and the safety
hoop (23).
3. Retighten the hexagon nuts (25).

Maintenance
7 Maintenance
7.1 Maintenance
NOTE
Carry out a function test of the tension wheel assembly every two years.
7.1.1 Function test in the tension wheel assembly
1. Place a spirit level on the outer face of the wheel body and check that the
wheel is vertical.
2. Check if the position of the weights is in accordance with the adjustment
graphic.
3. Move the weights to test the ease of movement of the wheel body and the
wires on the winding faces of the wheel hub and on the circumference of the
wheel body.
4. If the wire drags on the wheel body during movement, or if it runs over the
wound wire, readjust the tension wheel assembly.
5. Check the distance of the latching plate to the tension wheel assembly (see
8WL5070-0B" on page 39 and "Adjusting the distance between latching plate
and wheel body for 8WL5070-1" on page 40). If it is not 48 mm, readjust the
latching plate (see Section 6.5 "Final function test and readjustment on the
tension wheel assembly" on page 38).
6. Check the distances of the weight wire (17) to the safety hoop (23) (see
Section 6.5.3 "Adjusting the safety hoop for type 8WL5070-0B" on
page 40).
7. Inspect the steel wires for damage and replace any damaged wire.
8. Check all connections to the wires.
7.2 Repairs following a fault in the overhead contact line

7.2.1 Repairs following contact wire and/or catenary breakage
7.2.1.1 Visual inspection of the tension wheel equipment, wires and fixing elements for damage
Especially if high tensile forces are involved, the wheel rim can be damaged
when it engages during the latching operation. If damage is apparent on visual
inspection, replace the complete tension wheel assembly and the weight
suspension wire to ensure the safety of the equipment.
Inspect also the fixing elements and the pole support anchor for damage.

Maintenance
7.2.1.2 Function test on the tension wheel assembly

wheel is vertical.
wheel body.
graphic. If any deviations are found, correct the height only by adjusting the
length of the 1.5 m long section of the catenary wire/contact wire between
the catenary wire/contact wire and the insulator.
ATTENTION
The wedge-type dead-end clamp (17a) on the weight wire may no longer be moved. Moving it
would result in a deviation in the tension wheel assembly setting from the prepared adjustment
graphic.
page 40).
7.2.2 Repair following short-circuit with current flow through the tension wheel equipment
7.2.2.1 Visual inspection of the tension wheel equipment, wires and fixing elements for damage
NOTE
For safety, always carry out a visual inspection and replace any damaged parts before performing
a function test! Always replace the wire between the tension wheel assembly and the catenary
system.
7.2.2.2 Function test on the tension wheel assembly

wheel is vertical.
wheel body.

Maintenance
graphic. If any deviations are found, correct the height only by adjusting the
length of the 1.5 m long section of the catenary wire/contact wire between
the catenary wire/contact wire and the insulator.
ATTENTION
The wedge-type dead-end clamp (17a) on the weight wire may no longer be moved. Moving it
would result in a deviation in the tension wheel assembly setting from the prepared adjustment
graphic.
page 40).

Disassembly
8 Disassembly
8.1 Disassembly procedures
NOTE
When removing the tension wheel assembly from the overhead contact line system, note all safety
regulations and other procedures relevant to safety.
1. Fit contact wire stringing grips and a ratchet puller to secure the wire ropes
and steel wires to be removed.
2. Attach the weight set to a suitable lifting gear and release the connection
between weight set and weight wire.
3. Release the wire connection between the tension wheel assembly and the
catenary system.
4. Remove on the tension wheel assembly 8WL5070-1 the securing
elements (16) on the swing lever.
5. Lift the wheel body out of its suspension and lower it to the ground.
6. Remove the suspension from its mountings.
8.2 Recycling and disposal

The components of the tension wheel assembly have been made largely from
materials that can be recycled or disposed without harming the environment.
Dismantle the tension wheel assembly into its component parts and separate
them according to material.
In order to be recycled, the components must be in a condition that corresponds
to their intended use. Components that can not be recycled must be disposed
properly. The applicable legal requirements must be observed.
We can assist you with recycling. Please contact your local Siemens sales
office.

Technical data
9 Technical data
9.1 General data

Ambient temperature -40°C to +48°C
Efficiency ≥ 0.97
Mechanical advantage reduction ratio 1:3
Maximum tensioning force 40 kN
Maximum permissible length variation of contact and catenary wires 1.43 m
Weight
8WL5070-0B 32.5 kg
8WL5070-1 31.0 kg
9.2 Order numbers

Variants Order number
Tension wheel assembly up to 40 kN for guide tube up to d = 43.5 mm 8WL5070-0B
Tension wheel assembly up to 40 kN on structures 8WL5070-1
9.3 Materials of individual parts of the tension wheel assembly

Component Material
Wheel body ctAl (cast aluminium alloy)
Swing lever htgSt (steel, hot-dip galvanized)
Suspension htgSt (steel, hot-dip galvanized)
Latching plate AlMgSi (aluminium wrought alloy)
Guide tube bracket (strap and angle) htgSt (steel, hot-dip galvanized)
Safety hoop stlSt (stainless steel)
Screws, nuts, washers stlSt (stainless steel)
9.4 Accessories
Component Order number
Steel wire 50 mm2 (specify length when ordering) 8WL7090-0
Steel wire 50 mm2 with connecting fittings (7.5 m long) 8WL7090-0C

One-hole wedge (mlCl) 8WL1201-0
Two pin clevis link 19 (mlCl) 8WL1018-0
Guy clevis with pulley (mlCl) 8WL5167-5
Wedge-type dead-end clamp (mlCl) 8WL1180-7
Special wedge 50 (mlCl) 8WL1202-3

Abbreviations / definitions
10 Abbreviations / definitions
Variable Dimension unit Definition
a [m] Distance between eye of support bar and tension wire at lowest temperature and maximum
span length
Taken into account:
amin [m] Minimum distance between eye of support bar and tension wire at lowest temperature and
maximum span length
avar [m] Distance between eye of support bar and tension wire
aM [m] Distance between eye of support bar and tension wire in centre position
α [K-1] Coefficient of variation of length of contact and catenary wires to be tensioned
eo [m] Vertical distance of upper hook bolt axis from tension wire
eu [m] Vertical distance of lower hook bolt axis from tension wire
G - Upper surface of terrain
h [m] Minimum distance above terrain
LGF [m] Cutting length of weight guiding tube
LGS [m] Length of support bar
ΔL [m] Variation of length of contact and catenary wires to be tensioned
LR [m] Cutting length of tension wheel wire on the wheel rim
LT [m] Length of tension wheel wire on the wheel hub (drum)
lvar [m] Variable half of span length
lmax [m] Maximum half of span length
s [m] Distance between outer edge of wheel rim and pulley axis in centre position
ΔT [K] Temperature range of contact and catenary wires to be tensioned
Tmax [°C] Maximum temperature
Tmin [°C] Minimum temperature
Tvar [°C] Variable temperature of contact and catenary wires to be tensioned
WM - Number of wire turns in centre position
WR var - Number of wire turns on the wheel rim
WT var - Number of wire turns on the wheel hub (drum)

Siemens AG
Industry Sector
Mobility Division
Turnkey Systems
P. O. Box 3240
91050 Erlangen
Germany
electrification.mobility@siemens.com
www.siemens.com/mobility/electrification
Sicat 8WL5070
Operating Instructions / Version 1.1.5
A6Z08100028448 / Status: 2009-07-17
Subject to change without notice!

H7-Siemens 8WL5070-1

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Tension Wheel Assembly Sicat 8WL5070

Operating Instructions Version 1.1.5

Copyright © Siemens AG 2003 - 2009. All rights reserved.

2 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 3 / 48

4 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 5 / 48

2.1 Description of the warning notices

Symbol SIGNAL WORD

Symbol Signal word Meaning

Danger in the context of these operating instructions and the warning

Warning in the context of these operating instructions and the warning

Attention in the context of these operating instructions and the warning

Attention in the context of these operating instructions and the warning

Note in the context of these operating instructions is an important infor-

6 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

2.2 Intended use

2.3 Personnel qualification

In addition, all persons performing the installation, commissioning, operation

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 7 / 48

2.4 Safety requirements

Use personal protective equipment as specified by national accident prevention

8 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

2.5 Sources of danger

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 9 / 48

3 Purpose and use

10 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 11 / 48

1 wheel body 8 washer 13

* not included in the scope of delivery

Tension wheel assembly 8WL5070-0B

12 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

4.2.2 Tension wheel assembly 8WL5070-1

1 wheel body 8 washer 13

* not included in the scope of delivery

Tension wheel assembly 8WL5070-1

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 13 / 48

4.3 Possible arrangements

• parallel • above each other, offset

14 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

• one in front of the other

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 15 / 48

5 Transport and storage

5.1 Transport conditions

5.2.2 Tension wheel assembly with fitted wires (optional)

5.3 Checks on receipt

16 / 48 Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448

6.1 Tools and working equipment

Bolts Tightening torque

M12-A2-70 hexagon bolt 56 Nm

6.2.1 Calculations for rigging the tension wheel assembly

Sicat 8WL5070 / Operating Instructions / Version 1.1.5 / A6Z08100028448 17 / 48

6.2.1.1 Tension wheel assembly 8WL5070-0B

avar distance between eye of support bar and tension wire

Variation of length ΔL of contact and catenary wires

Formula ΔL = lmax * α * ΔT [m]

lmax maximum half of span length

Minimum distance h of tension wire above terrain

Formula h = 3 * ΔL + LGS + 0.50 [m]

ΔL variation of length of contact and catenary wires