SIST EN 50345:2009

SLOVENSKI STANDARD
SIST EN 50345:2009
01-september-2009
1DGRPHãþD
SIST EN 50345:2004
äHOH]QLãNHQDSUDYH6WDELOQHQDSUDYHHOHNWULþQHYOHNH,]ROLUQHYUYLL]VLQWHWLþQLK
YODNHQ]DSULWUGLWHYNRQWDNWQLKYRGQLNRY
Railway applications - Fixed installations - Electric traction - Insulating synthetic rope
assemblies for support of overhead contact lines
Bahnanwendungen - Ortsfeste Anlagen - Elektrischer Zugbetrieb - Baugruppen aus
isolierenden Kunststoffseilen im Fahrleitungsbau
Applications ferroviaires - Installations fixes - Traction électrique - Montages mettant en
oeuvre des câbles synthétiques pour le support des lignes aériennes de contact
Ta slovenski standard je istoveten z: EN 50345:2009
ICS:
29.280 (OHNWULþQDYOHþQDRSUHPD Electric traction equipment
SIST EN 50345:2009 en,fr
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 50345:2009

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SIST EN 50345:2009

EUROPEAN STANDARD
EN 50345

NORME EUROPÉENNE
June 2009
EUROPÄISCHE NORM

ICS 29.280 Supersedes EN 50345:2004


English version


Railway applications -
Fixed installations -
Electric traction -
Insulating synthetic rope assemblies
for support of overhead contact lines



Applications ferroviaires -  Bahnanwendungen -
Installations fixes - Ortsfeste Anlagen -
Traction électrique - Elektrischer Zugbetrieb -
Montages mettant en oeuvre des câbles Baugruppen aus isolierenden
synthétiques pour le support des lignes Kunststoffseilen im Fahrleitungsbau
aériennes de contact





This European Standard was approved by CENELEC on 2009-05-01. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: Avenue Marnix 17, B - 1000 Brussels


© 2009 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 50345:2009 E

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Foreword
This European Standard was prepared by SC 9XC, Electric supply and earthing systems for public transport
equipment and ancillary apparatus (Fixed installations), of Technical Committee CENELEC TC 9X, Electrical
and electronic applications for railways.
The text of the draft was submitted to the formal vote and was approved by CENELEC as EN 50345 on
2009-05-01.
This European Standard supersedes EN 50345:2004.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2010-05-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2012-05-01
This European Standard has been prepared under a mandate given to CENELEC by the European
Commission and the European Free Trade Association and covers essential requirements of EC Directive
2001/16/EC. See Annex ZZ.
__________

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Contents
Page
Introduction . 5
1 Scope. 5
2 Normative references . 6
3 Terms and definitions . 6
4 Characteristics of the rope . 7
4.1 General . 7
4.2 Client requirements . 8
4.3 Electrical requirements . 8
4.4 Mechanical requirements . 10
4.5 Environmental conditions . 11
4.6 Fire hazard . 11
4.7 Tracking and erosion . 11
5 Design, manufacture and workmanship . 11
6 Testing . 12
6.1 General . 12
6.2 Design tests for rope types . 12
6.3 Type tests . 15
6.4 Sampling test . 16
6.5 Manufacturer routine tests . 18
7 Component identification . 18
7.1 Rope identification . 18
7.2 Termination identification. 19
8 Verification of compliance. 19
8.1 Certification of compliance and test results . 19
8.2 Inspection and testing. 19
8.3 Test certificates . 19
8.4 Drawings . 20
9 Installation instructions . 20
10 Maintenance instructions . 20
11 Delivery and packaging . 21
11.1 Rope . 21
11.2 Terminations . 21
11.3 Insulators . 22
Annex A (informative) Intermediate clamps . 23
Annex B (informative) Mechanical, chemical and electrical recommendations . 24
Annex C (informative) Quality assurance . 26
Annex D (normative) Testing . 27
Annex ZZ (informative) Coverage of Essential Requirements of EC Directives . 28

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Figure
Figure 1. 14
Tables
Table 1 – Voltages excerpt from EN 50124-1, Table A.2 . 9
Table 2 . 9
Table 3 . 10
Table 4 . 13
Table 5 . 16
Table 6 . 17
Table D.1 – Element to submit to tests . 27

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Introduction
This European Standard has been prepared to provide general guidance and to define special requirements
for the design and testing of insulating synthetic ropes, their sheaths and their terminations for use in electric
traction overhead contact lines.
Special preferences will include such requirements as to comply with local procurement policies, working
practices, compatibility with existing systems, to combat environmental pollution and to provide a supporting
assembly with insulation which will give reliable service over its target life span.
These insulating synthetic ropes offer an alternative to the use of metallic cables associated with
conventional insulators.
1 Scope
This European Standard applies to the insulating synthetic ropes used in overhead contact lines.
This European Standard specifies the characteristics of insulating synthetic rope assemblies and is
applicable to electric traction overhead contact lines for railways, light railways, tramways, trolleybuses and
other systems.
These insulating synthetic ropes are utilised to provide mechanical support and electrical insulation for
overhead contact lines.
They are generally used in the following application fields:
 delta suspension of contact wires;
 catenary cable;
 mid point anchors;
 tie;
 dropper;
 headspan;
 noise and vibration damper;
 bridle- and pulley suspensions;
 cantilevers made of glass reinforced polymer (GRP).
This standard establishes the product characteristics, the test methods and checking procedures to be used
with the insulating synthetic ropes, together with the ordering and delivery requirements.
The object of this standard is to stipulate the provisions for the design and to allow the provisions of the
service indicated by the supplier to the purchaser or informed buyer.

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2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
EN 50119:2009, Railway applications - Fixed installations - Electric traction overhead contact lines
EN 50124-1:2001, Railway applications - Insulation coordination - Part 1: Basic requirements - Clearances
and creepage distances for all electrical and electronic equipment
EN 50125-2:2002, Railway applications - Environmental conditions for equipment - Part 2: Fixed electrical
installations
EN 50163:2004, Railway applications - Supply voltages of traction systems
EN 60695-11-10:1999 + A1:2003, Fire hazard testing - Part 11-10: Test flames - 50 W horizontal and vertical
flame test methods (IEC 60695-11-10:1999 + A1:2003)
EN 61109:2008, Insulators for overhead lines - Composite suspension and tension insulators for a.c.
systems with a nominal voltage greater than 1 000 V - Definitions, test methods and acceptance criteria
(IEC 61109:2008)
EN 62217:2006, Polymeric insulators for indoor and outdoor use with a nominal voltage > 1 000 V - General
definitions, test methods and acceptance criteria (IEC 62217:2005)
HD 588.1 S1:1991, High-voltage test techniques - Part 1: General definitions and test requirements
(IEC 60060-1:1989 + corrigendum March 1990)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
insulating synthetic rope
insulating rope composed of a core protected by a sheath
3.1.1
core of the rope
consists of synthetic fibres and is the load carrying component of the rope
3.1.2
sheath of the rope
envelope to protect the fibres and made of synthetic material, usually of a continuous polymeric material with
appropriate insulating qualities
3.2
termination
means to connect the ends of an insulating synthetic rope between two points
3.3
creepage distance
shortest distance along the surface of the insulating material between two conductive parts
[IEC 60050 (151-15-50)]
3.4
gauge length
distance between the centre lines of the termination anchoring pins or bolts

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3.5
insulator
assembly of an insulating synthetic rope and its associated terminations
3.6
class of insulator
insulator which has a specific design end fitting and a specific core/sheath combination
4 Characteristics of the rope
4.1 General
4.1.1 Common characteristics
Two major fibre types are used actually to provide the load carrying core. These are polyester and
polyaramid. Other fibre types having similar characteristics may also be used.
The fibre type is important in determining mechanical properties.
The sheath polymer type is important in determining durability, environmental performance and some
electrical and mechanical properties.
4.1.2 Specific characteristics of core materials
Insulating synthetic ropes with polyaramid or similar core fibres have a smaller diameter, greater tensile
fatigue resistance and smaller elongation (see B.1.1) than those of polyester or similar core fibres for a given
load carrying capacity and axial stiffness.
Insulating synthetic ropes with polyester or similar core fibres have a higher impact resistance than those of
polyaramid or similar core fibres, for example: from detached trolleybus poles.
Insulating synthetic ropes can operate within the following operational environmental temperatures:
 between –40 °C and +55 °C for polyester or similar;
 between –40 °C and +80 °C for polyaramid or similar.
4.1.3 Specific characteristics of sheath materials
The sheath may be composed of different materials. The type of material shall be chosen to withstand local
conditions as:
 U.V. exposure (e.g. polyethylene);
 general environmental conditions (e.g. polyethylene);
 abrasion effects (e.g. polyester / elastomer);
 flex effects (e.g. polyester / elastomer).

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When the rope is used in confined spaces (e.g. tunnels, stations, etc.) the sheath material shall have further
properties as:
 electrical tracking resistance (e.g. crosslinked polyethylene);
 antiflammability (e.g. crosslinked polyethylene);
 self-extinguishing (e.g. crosslinked polyethylene).
4.2 Client requirements
The client shall provide a comprehensive and specific description of the overhead contact line service
parameters and functioning requirements which may affect the design of the insulated synthetic rope.
This shall include, as appropriate, but not be limited to the following:
 electrical system service parameters;
 spatial and dimensional parameters;
 angular movement deflection limitations;
 maximum working loads required;
 environmental conditions;
 end fittings connection (terminations) requirements;
 any additional requirement for special tests;
 any special delivery or packaging requirements;
 identification of inspection and tests to be witnessed by the purchaser;
 service life of the insulator.
4.3 Electrical requirements
4.3.1 Voltages
Values of voltages are shown in Table 1. The rated insulation voltage and the test voltage levels are based
on statistical and risk consideration, which may affect the insulator during its service life.

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Table 1 — Voltages excerpt from EN 50124-1, Table A.2
Nominal voltages Rated insulation voltage Rated impulse voltage Power frequency
a
U  U U withstand voltage
Nm Ni
n
b
U
a
 kV kV
600 V d.c. 720 V d.c. 8 3,6
750 V d.c. 900 V d.c. 12 5,5
1 500 V d.c. 1 800 V d.c. 18 8,3
3 000 V d.c. 3 600 V d.c. 40 18,5
15 kV a.c. 36 kV a.c. 200 95
25 kV a.c. 52 kV a.c. 250 95
a
According to EN 50163.
b
According to EN 50124-1, Table B.1.

4.3.2 Creepage distances
Creepage distances shall be determined to withstand the highest permanent voltage of the system.
Consideration shall also be given to the type of insulating synthetic rope and its behaviour in polluted
conditions related to the whole life of the equipment.
The minimum creepage distance, for nominal voltages equal to or below 1,5 kV d.c. or 1 kV a.c. shall be
1 m.
NOTE This distance is based on practical experience.
For nominal voltages exceeding 1,5 kV d.c. or 1 kV a.c., an additional creepage distance per extra kV of the
nominal voltage shall be calculated from Table 2 and added to the minimum creepage distance.
EXAMPLE A 25 kV a.c. system with 45° inclination with no waterproof termination and for extreme unfavourable
conditions requires a total creepage distance of 3 040 mm.
Table 2
Additional creepage distances Waterproof termination No waterproof termination
Horizontal 45° inclination Horizontal 45° inclination
and vertical and vertical
mm/kV mm/kV mm/kV mm/kV
Normal operating conditions 30 35 45 55
Unfavourable operating conditions 40 45 60 70
Extreme unfavourable operating conditions 50 55 75 85
NOTE These values are based on practical experience.

The creepage distances may be reduced by agreement between purchaser and supplier.
The creepage distance values for nominal voltage up to 1,5 kV d.c. are valid for double insulation.

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4.4 Mechanical requirements
4.4.1 Terminations
The dimensions and the minimum breaking loads of the insulating synthetic ropes shall be as presented in
Table 3.
Table 3
Core fibre type Nominal external diameter of the rope Minimum specified breaking load of
the rope and its associated termination
mm kN
4,0 7,5
5,0 10,6
7,0 15,0
Polyaramid
8,5 30,0
a
or similar
9,0 45,0
11,0 60,0
13,5 105,0
5,0 3,0
6,0 4,0
7,0 5,0
8,5 10,0
Polyester
9,0 15,0
or similar
11,0 20,0
13,5 35,0
17 50,0
20 75,0
Tolerances on external diameter may be specified at the purchasing stage by the supplier.
a
The aramid fibre is equivalent to polyaramid fibre.

4.4.2 Permissible tensile loading
Refer to EN 50119:2009, 5.7.
4.4.3 Permissible tensile loading on a mid span connector (non-vertical load)
The maximum working load which can be applied to a mid span anchor shall not exceed 25 % of the
breaking load of the rope and its associated termination.
The breaking load of the mid span connector and rope combination shall be determined experimentally.
Account shall be taken of anticipated operating conditions and of the actual direction of applied loads.
4.4.4 Time dependant properties
The supplier shall provide information on the following insulating synthetic rope properties:
 fatigue behaviour (cycling loading);
 creep behaviour (under constant loading);
 stress relaxation behaviour (between two fixed anchors).

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4.4.5 Other mechanical properties
The supplier shall provide information on the load extension characteristics of the insulating synthetic ropes.
4.5 Environmental conditions
4.5.1 General
Insulating synthetic ropes shall operate within operational environmental conditions given in EN 50125-2.
Normal operating conditions exist when there is low industrial pollution, a low population density and no
thermal engines.
Unfavourable operating conditions exist when there is high industrial pollution and industrial gases, a high
population density, mixed railway operation, road traffic and frequent fog.
Extremely unfavourable operating conditions exist close to large power plants, chemical industry, smelting
works, with frequent fog or near the ocean.
4.5.2 Pollution
In addition to the electrical and mechanical performance requirements, the design shall address the
suitability of the sheath of the insulating synthetic rope surface to cater for levels of pollution which are likely
to be encountered during its service life (for example: the ability of the sheath to shed water or pollutants
from the surface and the ability of the system to withstand wetting by salt water in coastal applications).
4.5.3 Corrosion
The terminations and mid span connectors shall be suitably protected from corrosion and compatible with
interface connections. When appropriate, attention shall be given to protection against moisture ingress,
chemical activity or the influence of temperature variations or unidirectional current flow.
4.5.4 UV resistance
The composition of the sheath of the insulating synthetic ropes shall be suitably chosen to take into account
the effects of local UV radiation levels which are likely to be encountered during its service life.
4.6 Fire hazard
Fire hazard risks associated with each application should be assessed and appropriate core fibres and
sheath polymer types selected.
Special attention shall be paid to the possibility of gas emissions for applications in confined spaces, e.g.
tunnels, stations, etc.
4.7 Tracking and erosion
In addition to the electrical and mechanical performance requirements, the design shall address the
suitability of the sheath of the insulating synthetic rope surface to cater for damage from tracking and erosion
under conditions which are likely to be encountered during its service life.
5 Design, manufacture and workmanship
The insulating synthetic ropes shall be designed and manufactured in accordance with best practice, taking
cognisance of the system in which they will operate and with the need to design end terminations to match
specific rope sizes and types. All material shall be of the quality and of the type most suitable for working
under conditions specified for the full service life of the insulating synthetic ropes.

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The supplier shall provide a safety case for insulating synthetic ropes with novel or innovative features not
previously used within the railway environment. The safety case shall quantify any additional risks and
indicate how these risks are controlled.
Whenever a waterproof termination is specified, the manufacturer of the termination shall produce an extra
assembly guide.
6 Testing
6.1 General
The necessary tests and the elements to which these tests are to be applied are given in Annex D.
6.2 Design tests for rope types
6.2.1 General
The design tests are intended to verify the suitability of the design materials and the method of manufacture.
When an insulator is submitted to the design tests, the results shall be considered valid for the whole class of
the insulator which are represented by the one test and have the same named characteristics.
The design tests shall be performed on three specimens.
The following tests shall be performed for each class of test:
 breaking test;
 endurance test;
 electrical test (dry power frequency withstand voltage test and test of tracking and erosion for housing);
 flammability test.
6.2.2 Test specimens and preliminary tests
6.2.2.1 Product identification and labels
Each synthetic rope shall be marked with the name or trademark of the manufacturer, the year of
manufacture and the diameter of the rope. These identifications shall be printed every metre legible and
indelible. For a correct identification, see Clause 7.
6.2.2.2 Visual check and dimensions (drawing)
The dimensions of the tested synthetic ropes shall be checked in accordance with the relevant drawings,
taking note of any special tolerances. In addition, the rope sheath shall be checked visually in order to detect
any surface defects such as cracks, grooves, inclusions, etc.
6.2.2.3 Breaking test
For this test the sample lengths shall be at least equal to 1,0 m.
The test samples shall be subjected to a tensile load by a testing machine. The tensile load shall be
increased from zero, smoothly with an extension rate between 10 % and 20 % of the gauge length per
minute, up to the mechanical failure of the synthetic rope.

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The rope passes the test if the average value of the three samples shall exceed the minimum specified
breaking according to Table 3 and, for each tested sample, the recorded breaking load value shall exceed
95 % of the minimum specified breaking load.
6.2.2.4 Endurance test
A cyclic load shall be applied for this test. The sample lengths shall be at least equal to 0,9 m.
The mean load shall be equal to 30 % of the minimum specified breaking load for rope as given in Table 4.
The maximum and minimum loads shall be applied to ± 15 % of the mean load as shown in Figure 1.
Table 4
Endurance test load
Core fibre Nominal external Minimum specified
type diameter breaking load of the rope
mean minimum maximum
mm kN kN kN kN
4,0 7,5 2,25 1,91 2,59
5,0 10,6 3,18 2,70 3,66
7,0 15,0 4,5 3,83 5,18
Polyaramid
8,5 30,0 9,0 7,65 10,35
or similar
9,0 45,0 13,5 11,48 15,53
11,0 60,0 18,0 15,3 20,7
13,5 105,0 31,5 26,78 36,23
5,0 3,0 0,9 0,77 1,04
6,0 4,0 1,2 1,02 1,38
7,0 5,0 1,5 1,28 1,73
8,5 10,0 3,0 2,55 3,45
Polyester
9,0 15,0 4,5 3,83 5,18
or similar
11,0 20,0 6,0 5,1 6,9
13,5 35,0 10,5 8,93 12,08
17 50,0 15,0 12,75 17,25
20 75,0 22,5 19,13 25,88

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50%
40%
+15 % of mean load
30%
-15 % of mean load
20%
10%
0%
00,5 1

Time (s)
Figure 1
Unless other agreement between supplier and purchaser, the cyclic loading frequency shall be at maximum
of 10 cycles per second.
The rope passes the test if for each of the three samples the minimum number of load cycles to failure shall
6 6
3 x 10 cycles for polyaramid or similar fibres and 10 x 10 cycles for polyester or similar fibres exceed.
6.2.3 Dry power frequency withstand voltage test
For this test the creepage distance shall be equal to 1,0 m.
This test is performed on insulators and conducted in two part
...