O&M Manual - Elastic Support - W6341-6342 - 8WL4200 - en

Operating instructions / Version 1.2.
Elastic Support 25 kV AC
Sicat 8WL4200
for overhead contact line systems in tunnels and under structures
siemens.com/rail-electrification
Siemens AG, Mobility Division (MO) with the units listed below has been found to conform to
management system standards:
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
Certification was issued by the DNV GL Business Assurance Zertifizierung und Umweltgutachter GmbH
and confirmed by regular audits.
The certificate is valid for the following scope:
Project Planning, Acquisition, Engineering, Procurement, Production, Assembly, Commissioning and

Service of Products, Systems, Nets and Services in the Business Units Mobility Management (MO MM),
Mainline Transport (MO MLT), Urban Transport (MO UT), Turnkey Projects & Electrification (MO TPE),
Logistics and Airport Solutions (LAS) und Customer Services (MO CS).
Issued by:
Siemens AG
Mobility Division
Turnkey Projects & Electrification
Rail Electrification
Mozartstraße 33b
91052 Erlangen
Germany
E-Mail: techcom.re.mobility@siemens.com
Subject to change without notice!
© Siemens AG 2016
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.
Sicat 8WL4200
2 / 32 Operating instructions / Version 1.2.0 / A6Z08100028421
Content
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Fastening to a structure with circular cross-section
(e.g. arched tunnel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Fastening in rectangular tunnel or underpass with limited space 14
4.5 Fastening in rectangular tunnel or underpass . . . . . . . . . . . . . . . 15
5 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Mode of functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.1 Transport conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Checks on receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.1 Total load moment M and direction of force . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1.2 Calculation of the angle a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2 Auxiliary material ...................................... 20
7.2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2.2 Tightening torque values for bolts and nuts
to DIN VDE 0216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.3 Installation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sicat 8WL4200
Operating instructions / Version 1.2.0 / A6Z08100028421 3 / 32
7.3.1 Installation of subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.3.2 Settings on the basic element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3.3 Adjusting the contact wire height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.3.4 Checking the load at the rubber-bonded metal bushing . . . . . . . . . . . . . . . . . . 23
7.3.5 Adjusting the friction element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.2 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.1 Recycling and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.1 Variants and order numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11.4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.5 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Sicat 8WL4200
General 1
1 General
These Operating instructions are valid for the standard version of the product Sicat 8WL4200 as from
model year 2015.
The operating instructions (according to IEC 82079-1:2012) 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, in project
specific documentation 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, erection, 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. Observe as well any additional project specific documentation, e. g.
circuit manuals etc.
If you require further information, or if special problems arise, that have not been referred to suffi-
ciently in the Operating 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 repre-
sent 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 extended nor limited by the explanations given
in these Operating instructions .
Sicat 8WL4200
2 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 utilized 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.
Caution 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 corre-
sponding safety measures are not obeyed.
Caution 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 corre-
sponding safety measures are not obeyed.
Note in the context of these Operating instructions is an important information

related to the product or to the respective section of the documentation, to
which special attention is to be drawn.
Sicat 8WL4200
Safety 2
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 9).
The use complies with the intended purpose if:

 the product is operated in accordance with the agreed terms of delivery and the stated technical
specification, and
 any supplied devices and special tools are used exclusively for the intended purpose and in accor-
dance with the appropriate instructions in these Operating 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 experience 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. EN 50110 in Europe).
Sicat 8WL4200
2 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 appli-
cable accident prevention regulations and legally binding safety instructions.
Irrespective of these, the following five safety rules according to EN 50110-1:2013 apply:
Note
Before starting the work, you have to:

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.
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 threatening 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 appli-
cable 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.
Caution
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.
Sicat 8WL4200
Purpose and use 3
3 Purpose and use

Elastic supports hold fixed-terminated or auto-tensioned overhead contact lines, allow them to be
lifted by a specified distance as the pantograph passes and dampen vibrations.
Elastic supports are used:
 in structures with a circular cross-section (such as arched tunnels)

 under structures with flat roofs and limited space conditions (rectangular tunnels)
 under bridges with low clear height
They can be used:
 for single or twin contact wires without catenaries

 for catenary systems if the messenger wire is routed separately or merges with a
second contact wire
The length of the contact wire varies with changing temperatures (longitudinal expansion). This longi-
tudinal expansion of the contact wire is compensated by the lateral (horizontal) movement of the
elastic support about the axis X–X (see Fig. 1 "Main components of the elastic support" on page 11).
Within their load limit (maximum 500 Nm), elastic supports can be subjected only to tensile load by
the contact wire. To route the contact wire in a staggered arrangement underneath long building
structures, elastic supports can be mounted offset from the track centreline. They are designed for use
in overhead contact lines with a nominal voltage of 25 kV AC. A continuous maximum voltage of
27.5 kV AC to EN 50163 is permissible.
In planning the mounting position of the elastic support, the creepage distance of 1200 mm and the
specified minimum distances between live and earthed components must be considered to ensure
sufficient insulation. The height by which the contact wire is lifted by the pantograph must be included
in the planning of minimum distances.
Where space is limited, the adjusting options of the elastic support allow it to be optimally
matched to:
 the vehicle clearance gauge

 the space to be kept free for the pantograph
 the maximum loading gauge
The maximum permissible running speed at structures where one elastic support is arranged for each
contact wire before and after the structure (e.g. under short bridges) can be 160 km/h.
The maximum permissible running speed at structures where more than two elastic supports are
arranged in succession for each contact wire (e.g. in tunnels) is 130 km/h.
Note
The prerequisite for the passage of elastic supports at the specified maximum permissible running
speeds is the installation of the elastic supports in accordance with the operating instructions and
the use of suitable pantographs.
Sicat 8WL4200
3 Purpose and use
Elastic supports are not suitable:
 for use in overhead line systems with a nominal voltage above 27.5 kV AC
 for support intervals at which the maximum permissible load is exceeded (see marked working
range at torsion element in Fig. 11 "The basic element" on page 22)
 where a change in inclination causes the contact wire to be pushed down and this force has to
be absorbed by the elastic support
Sicat 8WL4200
Design 4
4 Design
4.1 General
The main components of the elastic support are shown in Fig. 1: "Main components of the elastic
support" on page 11.
12 1 2 3 4 3a
11
10
5
X L1
14
9
13
5a
8
6
7
70
dimension in mm
X 1)
L
1 composite insulator 8 friction element

2 tube clamp cap 9 basic frame
3 cantilever arm (tube 55x6) 10 central joint
3a end cap 11 insulator cap
4 clamp holder 12 tube 55x6
5 contact wire clip (for single contact wire) 13 M16 locking bolt
5a twin contact wire clip (for twin contact wire) 14 mounting bracket (optional)*
6 clevis end fitting
7 rubber-bonded metal bushing (torsion element)
1) length for setting angle of ±25°

* not included in the scope of supply
Fig. 1: Main components of the elastic support
The contact wire is fixed to the contact wire clip (5) or (5a), which is mounted on the clamp holder (4).
The clamp holder is attached to the cantilever arm (3) and can be undone and moved for adjustment.
The tube clamp cap (2) is the connecting piece between composite insulator (1) and cantilever
arm (3). For installation, this connection can be undone to allow a final fine height adjustment of the
contact wire. After the fine adjustment, it is fixed with spring dowels. The connection between
composite insulator (1) and insulator cap (11) is made using a tube (12).
The insulator cap (11) and the clevis end fitting (6) form the connection to the central joint (10). The
clevis end fitting contains two threaded bores in pairs offset by 17.5°. The insulator cap (11) has two
oblong slots, each of which contains a M16 locking bolt (13).
Sicat 8WL4200
4 Design
The position of the bolts and the insulator cap determine the range of movement of the complete
cantilever (see "Fig. 2: "Installation possibilities of the elastic support" on page 12").
The M16 locking bolts (13) allow an adjustment of the cantilever.
locking bolt (13) locking bolt (13) locking bolt (13)

angle 0° angle -17.5° angle 0°
insulator cap rotated by 180°
10 11
+7,5°
+25°
13
+7,5°
°
-10
-25°
-7,5
6 13 13

10 central joint
11 insulator cap
13 M16 locking bolt
Fig. 2: Installation possibilities of the elastic support
The bearing on the side of the central joint (10) enables the complete cantilever to be swiveled hori-
zontally about the axis X–X.
The heart of the central joint (10) is a rubber-bonded metal bushing (7). Together with an adjustable
friction element (8), this bushing absorbs vibrations, dampens them and prevents contact wire vibra-
tions after a pantograph has passed the elastic support. The function principle is described in Section
5 "Function" on page 16.
The basic frame (9), optionally with mounting bracket (14), secures the elastic support to its mounting
surface. The mounting bracket (14) allows the elastic support to be mounted at the correct height. It
must be matched to the available space at the installation location.
Note
The mounting bracket (14) (see Fig. 1 "Main components of the elastic support" on page 11) is not
included as standard with the elastic support.
Sicat 8WL4200
Design 4
4.2 Variants
The versions listed in the table differ in their length and in the number of supported contact wires.
Lengths L and L1 are shown in Fig. 1: "Main components of the elastic support" on page 11. For other
lengths, please contact your nearest Siemens dealership.
Order No. Number of supported contact wires L* [mm] L1* [mm]
8WL4200-0 Single contact wire 1400 665
8WL4200-0C Single contact wire 1530 795
8WL4200-0A Twin contact wire 1420 695
8WL4200-0B Twin contact wire 1570 845
8WL4200-0D Twin contact wire 1740 1045
4.3 Fastening to a structure with circular cross-section

(e.g. arched tunnel)
The basic frame (9) (optionally with mounting bracket) is attached to the sloping, arched tunnel wall
as shown in Fig. 3: "Fastening in arched tunnel with basic frame and mounting bracket" on page 13.
14 9
90°
Line joining the contact points on the rail head
9 basic frame
14 mounting bracket
Fig. 3: Fastening in arched tunnel with basic frame and mounting bracket
Sicat 8WL4200
4 Design
4.4 Fastening in rectangular tunnel or underpass with

limited space
The basic frame (9) is attached to the horizontal tunnel roof with mounting bracket (14) as shown in
Fig. 4: "Fastening in rectangular tunnel with limited space" on page 14. To ensure the required insula-
tion, the specified minimum distances to live and earthed components must be met, also taking into
account the lifting action of the pantograph. The minimum distance to the mounting structure can be
established with a mounting bracket (14). The complete cantilever arm is fitted to the clevis end
fitting (6) with the insulator cap (11) in the same way as the arched tunnel version. The difference is
that the threaded holes in the clevis end fitting, which are offset by 17.5°, are used.
14 9 6 11
90°
X

9 basic frame
11 insulator cap
14 mounting bracket
Fig. 4: Fastening in rectangular tunnel with limited space
Sicat 8WL4200
Design 4
4.5 Fastening in rectangular tunnel or underpass
The basic frame (9) (optionally with mounting bracket) is attached to the horizontal tunnel roof as
shown in Fig. 5: "Fastening in rectangular tunnel with basic frame and mounting bracket" on page 15.
The complete cantilever arm is fitted to the clevis end fitting (6) with the insulator cap (11)
rotated by 180°.
Any differences in height can be compensated with a mounting bracket (14). If the height difference
is great, a soffit post can be used for mounting.
X
14
11
90°

9 basic frame
11 insulator cap
14 mounting bracket
Fig. 5: Fastening in rectangular tunnel with basic frame and mounting bracket
Sicat 8WL4200
5 Function
5 Function
5.1 General
The pantograph of a locomotive lifts the elastic support and therefore the complete cantilever (canti-
lever arm, composite insulator). Once the locomotive has passed, the cantilever returns to its original
position. The vibration that this causes are absorbed and damped by this type of elastic support.
When configuring, mounting and adjusting elastic supports, observe the distances to adjacent
supports, the weight of the contact wire, the tensile force of the contact wire and the load-bearing
capacity.
5.2 Mode of functioning
For this section, refer to Fig. 6: "The basic element" on page 17.
The elements with an active function in this process are the rubber-bonded metal bushing (7) as
torsion element and the friction element (8). The rubber-bonded metal bushing (7) provides a
counter-torque to the weight of the contact wire, the cantilever and the lateral tensile force in the
central joint (10). The elasticity (spring energy) of the rubber in the socket is used to generate a
tension force.
When the pantograph passes, the pre-tension is relieved in the rubber of the rubber-bonded metal
bushing (7). The counter-torque causes the contact wire to be raised gently. After the pantograph has
passed, the cantilever returns to its original position. The rubber in the rubber-bonded metal
bushing (7) regenerates the tensile force. To allow an effective use of the torsion element, the rubber-
bonded metal bushing must be fitted with pretension (see Section 7 "Installation" on page 19).
Note
When the pantograph passes the elastic support, the rubber-bonded metal bushing must be
relieved within its working range (marked on the outer metal sleeve). If this range is exceeded, the
function of the elastic support is restricted.
The friction element (8) on the central joint (10) adds to the counterforce. The frictional resistance can
be changed through the pressure springs (16) on the friction element to match it to current conditions.
The stop (15a) in the T-piece (15) above the friction element (8) prevents the cantilever arm from
dropping down into the vehicle clearance gauge.
The stop (15b) in the T-piece (15) under the friction element (8) prevents the minimum distance
between the cantilever arm and the tunnel ceiling from being violated in the event of excessive lifting
of the contact wire (see Section 3 "Purpose and use" on page 9).
Sicat 8WL4200
Function 5
15
15a
15b
16
10
1 rubber-bonded metal bushing (torsion element)

7 friction element
9 basic frame
10 central joint
15 T-piece
15a stop
15b stop
16 pressure spring
Fig. 6: The basic element
Sicat 8WL4200
6 Transport and storage
6 Transport and storage
6.1 Transport conditions
The means of transport to and at the installation site must be suited to the transportation with respect
to construction and load capacity.
The notices on the packing regarding weight, lifting and transport have to be observed.
6.2 Packing
The product is delivered in a standard packing.
6.3 Checks on receipt
The shipment must be checked immediately on receipt for damage and for completeness based on the
delivery notes.
Note
If the consignment is damaged, the scope and cause of the damage is to be established, docu-
mented in writing and reported to the supplier without delay. The forwarding agent is to be enlisted
to record the facts if transport damage has occurred. A written record is essential for damage
claims.
6.4 Storage
If the elastic supports are stored outdoors, make sure they are protected from frost. To prevent dirt
deposits, cover the elastic supports.
Sicat 8WL4200
Installation 7
7 Installation
Note
IIn arched tunnels or other structures with circular clearance gauges, the complete cantilever arm
is installed in an upward position (see Fig. 3: "Fastening in arched tunnel with basic frame and
mounting bracket" on page 13). In rectangular tunnels with flat roofs or other straight structures,
the complete cantilever arm is installed in a downward position (see Fig. 5: "Fastening in rectan-
gular tunnel with basic frame and mounting bracket" on page 15).
7.1 Preconditions
7.1.1 Total load moment M and direction of force
Determine the total load moment M and the direction of the force for setting the angle  (0° to 8°) at
the central joint (10) (see Fig. 7: "Angle and dimensions at the elastic support" on page 19). The
setting defines the pretension of the rubber-bonded metal bushing (7).
°
30
70
0° -
10
Y M 0 - 2 84
X
+25 °
dimensions in mm
°
a = 0 °- 8
40°
-2 5°
7 X
7 rubber-bonded metal bushing

10 central joint
Fig. 7: Angle and dimensions at the elastic support
Sicat 8WL4200
7 Installation
7.1.2 Calculation of the angle 
Formula:  = M / c
c torsion constant (60 Nm/degree)

M total load moment (maximum 500 Nm)
Example:
The assumed total load moment M is 300 Nm. The above formula yields the setting angle  of 5°.
7.2 Auxiliary material
7.2.1 Tools
 spanner or rachet with socket sizes 13, 17, 19 and 24

 torque spanner (torque range 10 to 200 Nm) for sizes 19 and 24
 adjusting spanner 8WL4203-2 (not included in the scope of supply)
Fig. 8: Adjusting spanner 8WL4203-2
7.2.2 Tightening torque values for bolts and nuts

to DIN VDE 0216
Hexagon bolt M8-A2 16 Nm
7.3 Installation sequence
Below, the installation of a elastic support to a structure with circular cross-section is described.
Note
The mounting bracket (14) and the mounting materials for the basic frame (9) are not included in
the scope of supply.
Sicat 8WL4200
Installation 7
Choose the mounting height for the elastic support as specified in the project specification. Take into
account the applicable conditions, the required minimum distances and the contact wire height
adjustment possibilities. If necessary, use a mounting bracket (14).
7.3.1 Installation of subassemblies
The elastic support is supplied in three subassemblies:

 basic element (parts 6 to 11 and 13)
 composite insulator (1) with tube (12)
 cantilever arm (3) with tube clamp cap (2), clamp holder (4) and contact wire clip (5)
12 1 2 3 4 3a
11
10
17 5
X
14
9
13
7
X
6
1 composite insulator 8 friction element

2 tube clamp cap 9 basic frame
3 cantilever arm 10 central joint
3a end cap 11 insulator cap
4 clamp holder 12 tube
5 contact wire clip 13 M16 locking bolt
6 clevis end fitting 14 mounting bracket (optional)
7 rubber-bonded metal bushing 17 M16 hexagon bolt
Fig. 9: Individual parts on the elastic support
Start the installation of the elastic support as follows:

1. Drill four holes into the substructure in line with those in the basic frame (9) and suitable for the
mounting sundries (see Fig. 10: "Dimensions on the basic frame" on page 21) and fit the basic
frame.
240
125
18x39
80 40 dimensions in mm
Fig. 10: Dimensions on the basic frame
2. Place the tube (12) into the insulator cap (11) and clamp the tube.
Sicat 8WL4200
7 Installation
3. Connect the composite insulator (1) and the cantilever arm (3) at the tube clamp cap (2). For
coarse adjustment, set an angle between 0° and 30° and tighten the M16 hexagon bolt (17). The
clamp holder (4) with the required contact wire clip (5) is already fitted to the cantilever arm.
4. Clamp the composite insulator (1) onto the tube (12).
7.3.2 Settings on the basic element
15
15a
11
15b
13
10
18 A
A marked working range of the rubber-bonded metal bushing

7 rubber-bonded metal bushing
9 basic frame
10 central joint
11 insulator cap
13 M16 locking bolt
15 T-Piece
15a stop
15b stop
18 M12 hexagon bolt
Fig. 11: The basic element
1. Undo the M12 hexagon bolts (18) on the central joint (10).
2. Take the adjusting spanner (accessory). Place the end into a bore in the outer bushing of the
rubber-bonded metal bushing (7) and turn the bushing into the middle of the marked working
range (A). Hold this position.
3. Adjust axis X–X according to the reached angle  between 0° and 8° against the total load
moment M (tolerance ± 3°) and the calculated direction of force on the rubber-bonded metal
bushing. Use as your reference the vertical perpendicular to the horizontal of the top of rail (see
Fig. 7: "Angle and dimensions at the elastic support" on page 19).
Note
Angle  depends in the size of the calculated total load moment M and the calculated direction of
force application at the rubber-bonded metal bushing (see Section7.1.2).
4. Tighten the M12 hexagon bolts (18).
Sicat 8WL4200
Installation 7
7.3.3 Adjusting the contact wire height
1. Secure the contact wire in the contact wire clip (5).
Note
Observe the available space and the required minimum distances. The adjacent supports must be
taken into account when performing the of the contact wire height fine adjustment.
2. Undo the two M16 locking bolts (13) on the insulator cap (11) and perform a rough adjustment
of the contact wire height.
3. Retighten the two M16 locking bolts (13).
4. For contact wire height fine adjustment, undo the M16 hexagon bolt (17) so that the
cantilever (3) can be moved. Move the cantilever until the contact wire is at the required height.
5. Retighten the M16 hexagon bolt (17).
7.3.4 Checking the load at the rubber-bonded metal bushing
1. Simulate the passage of a pantograph. The working range (A) of the rubber-bonded metal
bushing (7) is marked on the outer metal bushing (see Fig. 11: "The basic element" on page 22).
The marking in the basic frame acts as a pointer. During the sequence of movement, the pointer
must not leave the marked working range. If it does leave the working range, repeat steps 2 to 5
of Section 7.3.3.
2. After fine adjustment, secure the relative position of composite insulator (1) and cantilever
arm (3) to each other.
Drill two Ø 6 mm to the side of the hexagon bolt (17) (see Fig. 12: "Fixing cantilever arm and
composite insulator" on page 23) in the tube clamp cap (2) and the composite insulator (1). Both
parts have a knockout that you can drill through.
1 17 2 3
0° -
0°3
19
1 composite insulator
2 tube clamp cap
3 cantilever arm (tube 55x6)
17 M16 hexagon bolt
19 spring dowel
Fig. 12: Fixing cantilever arm and composite insulator
3. Drive spring dowels (19) into the holes.
Sicat 8WL4200
7 Installation
7.3.5 Adjusting the friction element
1. Simulate a pantograph passing and observe the vibration behavior of the elastic support.
Note
The length of the pressure springs (16) at the friction element (8) is factory-set to 23.5 mm.
Spring pretension limit:
 minimum force at a spring length of up to 26 mm
 maximum force at a spring length of at least 20 mm
2. If the generated frictional force of the friction element (8) is not sufficient, to dampen the vibra-
tions, the friction resistance at the friction faces must be increased. To do this, adjust the spring
travel of the pressure springs (16) (see Fig. 13: "Pressure springs on the friction element" on
page 24).
3. Reduce the travel of both pressure springs (16) by turning the inner hexagon nuts (22a).
4. Having made the adjustment, secure the new position with the hexagon nuts (22b).
15
21
22b
22a 20
24
26
16 ... 10
20
25
27
dimension in mm
9 basic frame 22a M12 hexagon nut

10 central joint 22b M12 hexagon nut (counternut)
15 T-piece 24 M12 hexagon bolt
16 pressure spring 25 friction lining
20 M12 hexagon bolt 27 M12 hexagon nut
21 jaw
Fig. 13: Pressure springs on the friction element
5. If the T-piece (15) does not engage vertically with the jaw, readjust the position of the jaws (21)
at the central joint (10). To do this, undo and remove the two screw-couplings (20) and (27).
6. Select the suitable holes in the central joint (10) for the new position and refit the jaws (21) as
appropriate.
Sicat 8WL4200
Installation 7
Note
The stop (15a) prevents the cantilever arm from dropping down into the vehicle clearance gauge.
7. Drive a spring dowel above the jaws into the T-piece (15) (distance from the jaw, about
12 ± 5 mm) (see Fig. 11: "The basic element" on page 22).
The spring dowel acts as a stop (15a).
Note
The stop (15b) prevents the minimum distance between the cantilever arm and the tunnel ceiling
from being violated in the event of excessive lifting of the contact wire.
Drive a spring dowel below the jaws into the T-piece (15) (distance from the jaw, about 12 ± 5 mm)
(see Fig. 11: "The basic element" on page 22).
The spring dowel acts as a stop (15b).
Sicat 8WL4200
8 Commissioning
8 Commissioning
Danger
Incorrectly performed installation work presents a risk of physical or fatal injury. The installation
must be commissioned by appropriately qualified, trained, personnel.
Before the overhead contact line is put into operation, check that all components of the elastic
supports have been installed correctly.
Check all settings, such as the working range of the rubber-bonded metal bushing (7).
Sicat 8WL4200
Maintenance 9
9 Maintenance
9.1 Inspection
Carry out an annual inspection of the elastic supports.
In particular, test the behavior of the elastic support during passage of a pantograph.
Part to be inspected Inspection activity Evaluation and consequence
Rubber-bonded metal Check movement of rubber-bonded metal If the bushing is no longer working within the
bushing (7) bushing in the marked working range. marked range, perform a repair.
Friction element (8) Check degree of wear of the friction Worn friction linings can not generate the
surface on the jaws. required friction force. This causes a deterio-
ration of the elastic support's oscillation beha-
vior. Replace the friction element.
Composite insulator (1) Inspect for dirt deposits on the surface. Deposits impair the insulating properties. If
contaminated, clean the composite insulator.
Note
If the rubber-bonded metal bushing is no longer working in the specified working range, an
overload will result. The elastic support functions badly or not at all.
9.2 Service
Note
Corrosive cleaning agents can attach or destroy the plastic of the compound insulator.
Use only plastic cleaning solutions or a soap solution for cleaning.
If contaminated, clean the composite insulator. Use soft cleaning materials and plastic cleaning solu-
tions. Soap solution is often sufficient for cleaning.
Remove any worn material from the jaws (21) of the friction element.
9.3 Repair
Use only original Siemens parts for repairs.
Sicat 8WL4200
10 Disassembly
10 Disassembly
Danger
Serious personal injury and even death can be caused if the bolted connections of components
connected to the contact wire are unable to absorb the tensile forces exerted when the contact wire
is tensioned.
In operation, the contact wire is installed at high tensile force.
Work on live systems must be carried out only by qualified electricians.
Observe the safety notes in Section 2.4 "Safety requirements" on page 8.
1. Remove all tensile forces from the elastic support.

2. Undo the locking bolts (13) at the central joint (10).
3. Undo the bolt connection of the contact wire clip (5) and remove the contact wire from the
contact wire clip.
4. Undo the connection between insulator cap (11) and composite insulator (1).
5. Pull the complete cantilever arm off the tube (12) and place it down.
6. Hold the basic frame (9) and, if used, the mounting bracket (14) and undo the locking bolts from
the building structure.
7. Place the basic frame (9) and the mounting bracket (14) down.
8. Remove the friction element (8) and the central joint (10).
9. Remove the rubber-bonded metal bushing (7) from the central joint (10).
10. Separate the insulator (1) from the cantilever arm (3).
11. Remove the clamp holder (4) from the cantilever arm (3) and remove the contact wire clip (5).
12. Sort all components according to material and dispose of them for recycling.
10.1 Recycling and disposal
The parts of the elastic support are made mainly from recyclable or environmentally friendly materials.
A prerequisite for disposal is that the equipment must be in a condition corresponding to correct and
proper use. Make sure that you separate the products carefully according to material. Parts which
cannot be reused must be properly disposed of.
Observe the locally applicable legal regulations.
We can provide assistance with disposal. Please contact your local Siemens company.
Sicat 8WL4200
Technical data 11
11 Technical data
11.1 Variants and order numbers
Order number Design for Weight [kg] L* [mm] L1* [mm]
8WL4200-0 Single contact wire 18.38 1400 665
8WL4200-0C Single contact wire 18.70 1530 795
8WL4200-0A Twin contact wire 18.55 1420 695
8WL4200-0B Twin contact wire 18.93 1570 845
8WL4200-0D Twin contact wire 19.14 1740 1045
* Lengths L and L1 are shown in Fig. 1 "Main components of the elastic support" on page 11.
11.2 Technical Data
Contact wire according to EN 50149* AC-80 bis AC-150, Cu-ETP

AC-80 bis AC-150, CuAg0.1
AC-100 bis AC-120, CuMg0.5
Maximum bending moment 500 Nm
Torsion constant 60 Nm/Grad
Maximum running speed at 2 elastic supports arranged in succession 160 km/h
Maximum running speed at more than 2 elastic supports arranged in succession 130 km/h
Ambient temperature -40°C to +50°C
Nominal voltage AC 25 kV
Minimum creepage distance 1200 mm
* other types of contact wires on request
11.3 Materials
Component Material Abbreviation
Basic frame, central joint, clamp holder, Cast aluminium alloy ctAl
clevis end fitting, tube clamp cap
Torsion element Stainless steel, rubber stlSt
Composit insulator Glassfiber-reinforced plastic, silicone GRP
55x6 tubes Aluminium Al
Contact wire clip Copper-aluminium alloy CuAl
End cap Plastic-soft -
Bolts, nuts, washers, spring washers Stainless steel stlSt
Sicat 8WL4200
11 Technical data
11.4 Accessories
Description Order number
Adjusting spanner* 8WL4203-2
* The 8WL4203-2 adjusting spanner is not included in the scope of supply with the elastic support.
11.5 Spare parts
Description Order number
Friction element, complete 8WL4203-4
Sicat 8WL4200
Technical data 11
Sicat 8WL4200
Siemens AG
Mobility Division
Turnkey Projects & Electrification
Rail Electrification
Mozartstraße 33b
91052 Erlangen
Germany
electrification.mobility@siemens.com
www.siemens.com/rail-electrification
Sicat 8WL4200
Operating instructions / Version 1.2.0
A6Z08100028421 / Status: 24.08.2016
Subject to change without notice!
www.siemens.com

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Operating instructions / Version 1.2.

The certificate is valid for the following scope:

Project Planning, Acquisition, Engineering, Procurement, Production, Assembly, Commissioning and

Subject to change without notice!

3 Purpose and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Death, serious physical injury and damage to property can occur.

2.1 Description of the warning notices

Symbol Signal word

Symbol Signal word Meaning

Note in the context of these Operating instructions is an important information

2.2 Intended use

The use complies with the intended purpose if:

2.3 Personnel qualification

A person is qualified if he/she is familiarized with:

Please refer to national regulations (e. g. EN 50110 in Europe).

2.4 Safety requirements

Before starting the work, you have to:

Use personal protective equipment as specified by national accident prevention regulations.

2.5 Sources of danger

Risk of fatal injury through high voltage at the electrical system.

3 Purpose and use

Elastic supports are used:

 in structures with a circular cross-section (such as arched tunnels)

They can be used:

 for single or twin contact wires without catenaries

 the vehicle clearance gauge

Elastic supports are not suitable:

1 composite insulator 8 friction element

1) length for setting angle of ±25°

locking bolt (13) locking bolt (13) locking bolt (13)

6 clevis end fitting

Order No. Number of supported contact wires L* [mm] L1* [mm]

8WL4200-0 Single contact wire 1400 665

8WL4200-0C Single contact wire 1530 795

8WL4200-0A Twin contact wire 1420 695

8WL4200-0B Twin contact wire 1570 845

8WL4200-0D Twin contact wire 1740 1045

4.3 Fastening to a structure with circular cross-section

4.4 Fastening in rectangular tunnel or underpass with

6 clevis end fitting

4.5 Fastening in rectangular tunnel or underpass

6 clevis end fitting

5.2 Mode of functioning

1 rubber-bonded metal bushing (torsion element)

6 Transport and storage

6.1 Transport conditions

The product is delivered in a standard packing.

6.3 Checks on receipt

7.1.1 Total load moment M and direction of force

Line joining the contact points on the rail head

7 rubber-bonded metal bushing

7.1.2 Calculation of the angle 

c torsion constant (60 Nm/degree)

7.2 Auxiliary material

 spanner or rachet with socket sizes 13, 17, 19 and 24

Fig. 8: Adjusting spanner 8WL4203-2

7.2.2 Tightening torque values for bolts and nuts

Hexagon bolt M8-A2 16 Nm

Hexagon bolt M10-A2 32 Nm

Hexagon bolt M12-A2 56 Nm

Hexagon bolt M16-A2 135 Nm

7.3 Installation sequence