Metro OCS Component Identification Atlas (Insulators & Arresters / Rigid / Flexible)

Abstract

This atlas brings together photographic identification material for the components commonly used in metro overhead contact systems, arranged systematically in three groups - insulators and surge arresters, rigid suspension and flexible suspension - comprising 20 plates covering more than 80 components. Each plate is matched to a photograph and a three-column record of "name / model / remarks", for use in OCS maintenance, pre-assembly, stocktaking, training and the induction of new staff, and also as a supporting reference for component acceptance by project departments.

Keywords: metro OCS; component identification; insulator; surge arrester; rigid suspension; flexible suspension; registration arm; dropper clamp; registration ring; suspension pulley

1. Identification Plates for Insulators and Surge Arresters (INSULATOR & ARRESTER)

Related products: Insulators · Surge arresters · Support brackets

JA rod type JB rod type Anchoring insulator Return box busbar Pin insulator SA rod type Surge arrester

1. Group identification of rod type, anchoring and busbar insulators — Fig. 1-1 Group identification of rod type, anchoring and busbar insulators (click to enlarge)

1. Identification of pin type, SA type and surge arrester — Fig. 1-2 Identification of pin type, SA type and surge arrester (click to enlarge)

Key points: the plates summarise the 7 classes of insulator and arrester commonly used in metro overhead contact systems: the JA rod type insulator (cantilever lower base), the JB rod type insulator (cantilever upper base), the anchoring insulator (model XJ-1.5A), the return box busbar insulator, the pin insulator (rigid registration point), the SA rod type insulator (at the rigid-to-flexible transition) and the surge arrester used in depots. Each item corresponds on site to a different installation position and electrical isolation duty, and can be located quickly during maintenance by checking the nameplate against the three columns of name, model and remarks.

2. Identification Plates for Rigid Suspension Components (RIGID CATENARY)

Related products: Connections and fasteners · Electrical bonding · Support brackets

Earth clamp backing plate T-head bolt Bonding clamp Busbar registration clamp Silicone rubber cross brace Centre anchor clamp Chemical anchor Overhead earth wire anchorage

2. Earth clamp backing plate / T-head bolt / bonding clamp — Fig. 2-1 Earth clamp backing plate / T-head bolt / bonding clamp (click to enlarge)

2. Bonding clamp / earthing ring / busbar registration clamp / centre anchor insulating rod — Fig. 2-2 Bonding clamp / earthing ring / busbar registration clamp / centre anchor insulating rod (click to enlarge)

2. Busbar registration clamp / insulating cross brace / suspension channel type B and A — Fig. 2-3 Busbar registration clamp / insulating cross brace / suspension channel type B and A (click to enlarge)

2. Cable fixing bracket / busbar centre anchor clamp / busbar bonding clamp / chemical anchor — Fig. 2-4 Cable fixing bracket / busbar centre anchor clamp / busbar bonding clamp / chemical anchor (click to enlarge)

2. Terminal anchor clamp / adjusting bolt / overhead earth wire clamp / overhead earth wire anchorage base — Fig. 2-5 Terminal anchor clamp / adjusting bolt / overhead earth wire clamp / overhead earth wire anchorage base (click to enlarge)

2. Opposed anchorage mounting base for overhead earth wire — Fig. 2-6 Opposed anchorage mounting base for overhead earth wire (click to enlarge)

Key points: rigid suspension components are mostly used in the busbar overhead contact systems of metro tunnels, and include the earth clamp backing plate (GXJL14-99), T-head bolt, bonding clamps (CJL05-98 D3/D1, CJL04-98 Z), earthing ring, busbar registration clamps (GXJL02-99 B/C), silicone rubber centre anchor insulating rod, silicone rubber insulating cross brace, suspension channels (type B and type A), cable fixing bracket (GXJL25-99 A), busbar centre anchor clamp (GXJL05-99), busbar bonding clamp (GXJL04-99), chemical anchor (RM20×270), terminal anchor clamp (CJL27-98 T120), adjusting bolt (CJL89-98), overhead earth wire clamp, overhead earth wire anchorage base and opposed anchorage mounting base (GXJL16-99), more than 20 items in all.

3. Identification Plates for Flexible Suspension Components (FLEXIBLE CATENARY)

Related products: Contact suspension · Registration devices · Tensioning devices · Electrical bonding

Dropper clamp Registration arm Registration ring Twin link plate Anchor clamp Bonding clamp Balance weight rod Suspension pulley

3. Twin messenger wire dropper clamp / sling clamp / dropper protective sleeve — Fig. 3-1 Twin messenger wire dropper clamp / sling clamp / dropper protective sleeve (click to enlarge)

3. Type D1 twin link plate / twin messenger wire anchor clamp / socket saddle / ball eye — Fig. 3-2 Type D1 twin link plate / twin messenger wire anchor clamp / socket saddle / ball eye (click to enlarge)

3. Type GDC(B) bonding clamp / anchor rope fixing clamp / U-bolt clamp / type T1 balance weight rod — Fig. 3-3 Type GDC(B) bonding clamp / anchor rope fixing clamp / U-bolt clamp / type T1 balance weight rod (click to enlarge)

3. Long registration single ring / long registration double ring / direct contact wire bonding clamp / contact wire registration clamp — Fig. 3-4 Long registration single ring / long registration double ring / direct contact wire bonding clamp / contact wire registration clamp (click to enlarge)

3. Type CL3 registration arm / sling clamp / type 120 clamp / type 60 long registration post — Fig. 3-5 Type CL3 registration arm / sling clamp / type 120 clamp / type 60 long registration post (click to enlarge)

3. Type 48 long registration post / type 50 double-ear wedge clamp / split pin / wire ring — Fig. 3-6 Type 48 long registration post / type 50 double-ear wedge clamp / split pin / wire ring (click to enlarge)

3. Connecting clamp / type T1 triangular adjusting plate / registration ring clamp / type 300 double ring rod — Fig. 3-7 Connecting clamp / type T1 triangular adjusting plate / registration ring clamp / type 300 double ring rod (click to enlarge)

3. Guy twin link plate (small and large) / twin wire support clamp / type 1 pipe cap — Fig. 3-8 Guy twin link plate (small and large) / twin wire support clamp / type 1 pipe cap (click to enlarge)

3. Type 1 modified registration tube clip / connecting shackle / registration double ring / type ZG60 long registration ring — Fig. 3-9 Type 1 modified registration tube clip / connecting shackle / registration double ring / type ZG60 long registration ring (click to enlarge)

3. Type G34 registration ring / type 34 support / type 48 registration ring / type ZG60 sleeve double ear — Fig. 3-10 Type G34 registration ring / type 34 support / type 48 registration ring / type ZG60 sleeve double ear (click to enlarge)

3. Registration double ring (S60) / type G60 registration ring / twin wire copper suspension pulley / single wire copper suspension pulley — Fig. 3-11 Registration double ring (S60) / type G60 registration ring / twin wire copper suspension pulley / single wire copper suspension pulley (click to enlarge)

3. Long bolt / hoop — Fig. 3-12 Long bolt / hoop (click to enlarge)

Key points: the flexible suspension group covers more than 50 commonly used components, which by function fall into the following groups. (1) Slings - twin messenger wire dropper clamp (CJL02(SC)-2001), sling clamp (CJL01(D)-2001), dropper protective sleeve (001-CW-13-026). (2) Link plates and anchorages - type D1 twin link plate (CJL42(D1)-98), twin messenger wire anchor clamp (CJL39-98), socket saddle (CJL17-99-T), ball eye, anchor rope fixing clamp (CJL38-98), U-bolt clamp (001-CW-13-121), type T1 balance weight rod (CJL46(T1)-2001). (3) Registration - long registration single ring (CJL13(L)-98), long registration double ring, direct contact wire bonding clamp (CJL04(Z)-98), contact wire registration clamp, type CL3 registration arm (CJL63(CL3)-2001), type 120 clamp, type 60/48 long registration posts (CJL82-98), type 50 double-ear wedge clamp with split pin, wire ring, connecting clamp (CJL94-98), type T1 triangular adjusting plate (CJL88(T1)-98), registration ring clamp (CJL12-98), type 300 double ring rod (CJL55(300)-98). (4) Guys and pipe caps - guy twin link plate (small and large) (CJL42-98), twin wire support clamp (CJL18(L)-98), type 1 pipe cap (JL07(1)-99). (5) Registration clips - type 1 modified registration tube clip (CJL35(1)-98), connecting shackle (CJL403-2004), registration double ring (CJL12(S48)-98), type ZG60 long registration ring (JL13(ZG60)-04), type G34 registration ring (JL12(G34)-04), type 34 support (CJL09(34)-2001), type 48 registration ring (JL12(G48)-04), type ZG60 sleeve double ear (JL14(ZG60)-04), registration double ring (CJL12(S60)-98), type G60 registration ring (JL12(G60)-04). (6) Pulleys and hoops - twin wire copper suspension pulley (CJL77(S)-98), single wire copper suspension pulley, long bolt, hoop.

Notes on Use

Further reading: Contact suspension systems · Insulators · Registration clamps · Connections and fasteners · Surge arresters · Tensioning devices

This atlas contains 20 identification plates covering more than 80 components, spanning the full range of typical metro OCS scenarios from insulation and protection through rigid suspension to flexible suspension.
The three columns of "name / model / remarks" on each plate correspond to the nameplate of the actual item and can be used alongside the equipment on site or the stock records; a blank model column means that no model was marked on the original plate.
Unless otherwise stated, dimensions in the plates are in mm, torques in N·m and tensile forces in N.
Where a plate shows "Fig. X-N (click to enlarge)" at the bottom right, clicking the image opens the original size in a new tab, making it easier to examine details on site.
It is recommended to use this atlas together with the maintenance workmanship documents and equipment model lists currently in force in your own organisation; where there is any inconsistency with the latest regulations, the latest regulations prevail.

Scope of use: this atlas has been compiled from publicly available technical material and is intended solely for OCS maintenance, pre-assembly, training and the induction of new staff in rail transit; it is not for commercial use. The photographs were taken on engineering sites; where they are inconsistent with the latest industry standards or the manufacturer's technical documents, the latest versions prevail.

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