Shoresafe PST

Specification

Date of Origin: 10 November 2017

Revision Approval by
Revision Author Signature Details of Revision
Date Contractor
The design of the equipment is based on equipment supplied by Conductix-Wampfler for other rail depots in
the UK and around the world.
Power is supplied to the train via switchable trolleys running on an I-section beam suspended in the roof of
the depot. Single pole insulated conductor bars, supported on brackets fixed to the trolley running beam, are
used to feed both power and control circuits on the trolley.
1.0 Insulated Conductor Bar
A single 800A rated copper conductor bar is used on each road for the 750V dc supply to both traction and
auxiliary circuits. The control circuit on the trolley has a peak demand of less than 5A, therefore, two 160A
rated copper conductor bars are used on each road to supply the 110Vac to these circuits.

Bracket
Control bar hanger
Power bar hanger

Power conductor bar Control conductor bar

Trolley running beam

All conductor bars have a V-shaped self guiding contact surface. A rigid extruded PVC insulation cover
provides protection to IP2X, thereby offering significant safety improvements over old style non-insulated
busbars, which have been used for stinger applications in the past.
Conductor bars are supplied in 4.5m lengths and are joined together and supported by purpose made joints
and hangers. The hangers are fitted to brackets designed to be clipped to the top flange of the trolley running
beam. Anchor clamps are provided to ensure that the system does not move as a result of frictional forces
from the trolley collectors, and to guard against deformation as a result of the effects of thermal expansion
and contraction.
Power feed connectors are provided from within the range of standard conductor bar components. These
allow for connection of up to 4 cables of maximum 50mm2 to the 800A bar and up to 2 cables of maximum
95mm2 to each 160A bar.
At both ends of the system there are isolation sections of 4m length. In these sections neither power nor
control voltage are available. End covers are fitted at both ends of all conductor bars.
The conductor bar system and associated components, including the current collectors and collector shoes
that are mounted onto the trolley, comply fully with the requirements of BS 60204 (Parts 1 & 32).
Full details of the conductor bars and associated fittings can be found in the Safelec catalogue, which is
included as an attachment with this submission.

2.0 Pendant Switchable Trolley (PST)

One PST is provided. The trolley has the facility to be switched on and off by the operator and will be
interlocked such that it cannot be made live unless it is correctly inserted into the train receptacle. It is not
necessary to turn the overhead conductor bars on and off to ensure the train plug is dead, switching of power
to the plug is controlled by the trolley pendant closing and opening the trolley contactor. The overhead

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conductor can remain live without compromising the safety of the system, thus removing the need for
switchgear at each road end.
Drawing number M3246 shows a typical switching schematic for the traction supply.

The PST design is divided in to four major elements

1. The trolley and collector assembly
2. The contactor and control electronics enclosure
3. The Operator Trolley Control Pendant
4. The Output and Dropper lead assembly
Drawing number M3249 shows the General Arrangement for a generic PST identifying the major
components.

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2.1 The trolley and collector assembly
2.1.1 Trolley Mechanical Components
The trolley comprises a zinc plated steel chassis assembly configured to mount the PST onto the running
beam. The trolley runs on four flanged wheels incorporating sealed roller bearings. Two retaining angles are
incorporated into the trolley chassis assembly to retain the PST on the beam in the event of wheel assembly
failure. Integral to the trolley chassis are two towing arms, used to mount the collector arm assemblies.
2.1.2 Trolley Electrical Components
The trolley assembly is a generic design capable of being fitted with single or double 250A rated collectors,
dependent on the required system load, to provide 750Vdc power supply from the 800A rated insulated
conductor bar, and two single 100A collectors, to feed the 110Vac control circuits from the 160A rated
insulated conductor bar.
The collector shoes are of a copper graphite compound, which will, with use, provide a conductive patina on
the surface of the conductor bar, reducing friction and improving transfer of current between the bar and the
moving collector.
The collectors are articulated and sprung to provide tolerance for misalignment in both the vertical and
horizontal planes. The tolerances are:
Vertical Horizontal
250A power collector +70mm, -44mm ±63mm
100A control collector +80mm, -20mm ±63mm

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These tolerances are adequate to ensure continuity of contact between collector shoe and conductor bar in
any correctly installed rail depot application.

2.2 The Contactor and control electronics enclosure

The elements of the enclosure are divided as follows:
1. Mechanical enclosure
2. Electrical components
2.2.1 Mechanical Enclosure
The control enclosure is fabricated using 1.6mm mild steel plate on a formed angle framework. It has
removable covers, also in 1.6mm mild steel, to two sides. It is finished in a polyester powder coating.
On the underside of the enclosure are a pair of indicator beacons, which indicate the status of the plug.
Whenever the 110Vac control voltage is available to the trolley, one of the beacons is illuminated. When the
trolley is idle (contactor open), the white beacon is illuminated. When the contactor is closed or current is
flowing through a plug, the white beacon is extinguished, and the red beacon is illuminated.
2.2.2 Electrical components
The electrical components are divided into two main sections, the power circuits and the control circuits.
The components in the power circuit are:
1 off Microelettrica 600A rated contactor (Type LTHS320 2 pole)
1 off Mersen 500A 750Vdc Fuse
The components in the control circuit are:
1 off two pole 0.8A circuit breaker
1 off Current Transducer
2.3 Operator Control Pendant
The Operator Control Pendant is suspended beneath the enclosure and provides the means of operator
switching of the PST contactor. Each trolley has its own control pendant featuring a key operated “On” switch
and a red “Stop” button.

Pushbutton “OFF”

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2.4 Output Cable and Dropper Lead Assembly
The Output Cable and Dropper Lead Assembly is the main cable between the output of the trolley contactor
and the train. When the contactor is energised the lead carries the 750Vdc supply to the train. The lead is
fitted with the appropriate plug to suit the train receptacle.
The train plug, which is not yet specified, will be adapted to provide an interlock facility, such that the trolley
cannot be switched on unless the plug is fully inserted in the train socket.
The trolley drop lead has a frangible link which will separate in the event of a train driving out of the depot
with the shore supply still connected.

3.0 Electrical Specification

The PST and PSB are rated as follows
Voltage Rating (VDC) 900
PST (Traction) Current Rating (A) 500 - continuous
Rated Breaking Capacity (A) 600
Over Current Protection
DC Over Current trip level (A) 500
110 V ac Control supply (A) 1
Control Voltage Input (VAC) 110 (or 220Vac)
Power Requirements 110 V dc supply (A) 0.3
Trolley Weight (Kg) 85 max (dependant on cable lengths)

4.0 System Interfaces

4.1 Trolley running beam
The size of beam required for the trolley to run on is determined by a number of factors, principally the design
of the building steelwork. The design of the trolley chassis is such that, within a certain range, it can be
manufactured to suit the beam size specified by the building designer.
Drawing number M3250 shows the loading exerted by the stinger system to allow calculation of an
appropriate beam size.
The supply and installation of the trolley running beam is excluded from our scope of work.

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5.2 Train plug
The train plug will be fitted to the trolley drop lead cable. The plug will be adapted to provide an interlock
facility, such that the trolley cannot be switched on unless the plug is fully inserted in the train socket.
We will need a sample plug and socket assembly immediately after a contract is placed to enable us to
develop a suitable interlock mechanism. This will probably take the form of a proximity switch fixed onto the
plug which will actuate on part of the train socket, although we cannot finalise the design until we have a
sample plug and socket.
5.3 Power supply
The stinger system is designed to operate with a 750Vdc supply to provide power to the trains, and a 110Vac
supply to provide power for the trolley control circuit and indicator lights.
The PST control circuit has the following loadings per trolley:
250VA inrush load for the contactor
1A holding current
The provision of suitable power supplies and associated switchgear is excluded from our scope of work.
5.4 Power feed connection
Incoming supply cables are connected to the conductor bar using power feed connectors from the range of
standard components.
Connection boxes and cables for connection to the conductor bars are supplied; the dc connection box is
configured to accept 2 incoming cables of up to 1x185mm2 from the dc switchgear panel, four 1x50mm2
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outgoing cables of 1m length are supplied; the ac connection box is configured to accept 1 incoming cable of
up to 2x4mm2 from the ac supply, one 2x2.5mm2 outgoing cable of 1 m length is supplied. The incoming
cables are excluded from our supply.

6.0 Testing

All trolleys will be tested in accordance with our standard factory test procedure, 319074, a copy of which is
attached.

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