IEC 62499:2008

IEC 62499
Edition 1.0 2008-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Railway applications – Current collection systems – Pantographs, testing
methods for carbon contact strips

Applications ferroviaires – Systèmes de captage du courant – Méthodes
d'essais des bandes de frottement en carbone des pantographes

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IEC 62499
Edition 1.0 2008-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Railway applications – Current collection systems – Pantographs, testing
methods for carbon contact strips

Applications ferroviaires – Systèmes de captage du courant – Méthodes
d'essais des bandes de frottement en carbone des pantographes

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
R
CODE PRIX
ICS 45.060 ISBN 978-2-88910-743-8
– 2 – 62499 © IEC:2008
CONTENTS
FOREWORD.3
1 Scope.5
2 Normative references .5
3 Terms and definitions .5
4 Symbols and abbreviations.5
5 Tests .6
5.1 General .6
5.1.1 Type tests .6
5.1.2 Routine tests .6
5.2 Test procedures .6
5.2.1 Tests for the temperature characteristic of the carbon contact strip
under rated current loading.6
5.2.2 Test for deflection and extension of the carbon contact strip under
extremes of temperature.8
5.2.3 Test for flexural characteristic of the carbon contact strip .8
5.2.4 Test for shear strength of the contact strip.9
5.2.5 Test of autodrop detection sensor integral with contact strips .11
5.2.6 Test of mechanical fatigue resistance of the carbon contact strip .13
5.2.7 Test of the electrical resistance of the contact strip .13
Annex A (normative) List of tests .16
Annex B (informative) Parameters to be specified by the customer .17
Bibliography.18

Figure 1 – Arrangement of test device for testing temperature characteristic .7
Figure 2 – Example of current supply connection .7
Figure 3 – High temperature test.8
Figure 4 – Preparation of samples .9
Figure 5 – Example of suitable fixture for testing shear strength of carbon contact strip.10
Figure 6 – Example of testing configuration of shear strength test .10
Figure 7 – Typical impact test device .12
Figure 8 – Air supply and monitoring equipment.13
Figure 9 – Test of electrical transfer resistance from the carbon contact surface to the
supporting structure .14
Figure 10 – Connection scheme for test of electrical resistance .15

Table A.1 – Catalogue of tests.16

62499 © IEC:2008 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
RAILWAY APPLICATIONS –
CURRENT COLLECTION SYSTEMS –
PANTOGRAPHS, TESTING METHODS
FOR CARBON CONTACT STRIPS
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
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2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
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indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62499 has been prepared by IEC technical committee 9: Electrical
equipment and systems for railways. It is based on EN 50405:2006.
The text of this standard is based on the following documents:
FDIS Report on voting
9/1190/FDIS 9/1218/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

– 4 – 62499 © IEC:2008
The committee has decided that the contents of this publication will remain unchanged until
the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in
the data related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
62499 © IEC:2008 – 5 –
RAILWAY APPLICATIONS –
CURRENT COLLECTION SYSTEMS –
PANTOGRAPHS, TESTING METHODS
FOR CARBON CONTACT STRIPS
1 Scope
This International Standard gives rules for testing methods for carbon contact strips. The
purpose of this standard is to demonstrate that the carbon contact strip construction, by
attachment to integral supporting structure (carrier) but excluding bolted assembly, is fit for
purpose. Not all tests may be relevant to some designs.
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.
None.
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
carbon contact strip
strip of carbon material, permanently attached to an integral supporting structure (carrier) but
excluding bolted assemblies
3.2
shear strength
stress at failure of the adhesion between carbon and the support structure
3.3
autodrop detection sensor
mechanism incorporated in the carbon contact strip to provide the indication for the
pantograph automatic dropping device (ADD)
3.4
flow continuity
uninterrupted flow of air or other fluid
3.5
rated current loading
current value defined by the manufacturer that the carbon strip is designed to sustain without
degradation under the specified operating conditions
4 Symbols and abbreviations
A designed area of adhesion (mm )
F shear force (N)
S
– 6 – 62499 © IEC:2008
R resistance (Ω)
Τ shear strength (N/mm )
s
5 Tests
5.1 General
There are two categories of tests:
– type tests,
– routine tests.
The above tests are described in 5.1.1 to 5.1.2.
Supplementary tests may be required if they have been specified in the customer
specification and after agreement with the supplier.
Annex A summarises the tests which shall be performed.
5.1.1 Type tests
Type tests shall be performed on a single piece of product of a given design.
Equipment in current manufacture shall be considered to have satisfied the type tests; if the
manufacturer can provide certified reports of type tests already conducted on identical
components, the type tests shall be considered to be complied with.
5.1.2 Routine tests
Routine tests shall be carried out to verify that the properties of a product correspond to those
measured during the type test. Routine tests shall be performed by the supplier on each
equipment.
5.2 Test procedures
5.2.1 Tests for the temperature characteristic of the carbon contact strip under rated
current loading
5.2.1.1 General
The test aims to determine the temperature characteristic to stability of the carbon contact
strip at the maximum designed current loading.
5.2.1.2 Test method
The carbon contact strip shall be fixed at one end and freely supported at the other end (see
Figure 1). The current supply connection shall be made by clamping suitable interfaces to the
vertical faces of the carbon, but not in contact with the carrier material (see Figure 2). The
current take off shall be made at the normal design interface(s) between the carrier and the
pantograph.
62499 © IEC:2008 – 7 –
IEC  2191/08
Key
1 parallel clamp (steel)
2 carbon contact strip fixed end
3 temperature sensor 2 mm above carbon carrier interface
4 power supply
Figure 1 – Arrangement of test device for testing temperature characteristic

IEC  2192/08
Key
1 current supply connection (steel, copper)
Figure 2 – Example of current supply connection
The temperature shall be monitored adjacent to the current supply connection at a point 2 mm
above the carbon / carrier interface. The maximum rated current loading shall be applied to
the carbon contact strip until the monitored temperature remains constant and then for a
further 30 min. The temperature shall be continuously recorded during the test as a
temperature – time characteristic.
Test acceptance criteria: The carbon contact strip shall remain fit for purpose. The contact
strip shall remain in accordance with drawing at room temperature.

– 8 – 62499 © IEC:2008
5.2.2 Test for deflection and extension of the carbon contact strip under extremes of
temperature
5.2.2.1 General
The test aims to determine the vertical displacement and change in length of the carbon
contact strip under extremes of temperature.
5.2.2.2 Test method
5.2.2.2.1 High temperature test
This test may be carried out concurrently with the test described in 5.2.1. Under the steady
state heated conditions of 5.2.1.2, the change of length of the carrier (Δl) and vertical
displacement of the strip (Δh) from the room temperature condition shall be recorded by
means of an automatic data recorder (see Figure 3).

Δh
ΔI
IEC  2193/08
Key
1 carbon contact strip fixed
2 vertical displacement
3 change of length
Figure 3 – High temperature test
5.2.2.2.2 Low temperature test
The contact strip shall be cooled by a suitable method until the temperature of the strip is
–40 °C. The contraction and vertical displacement from the room temperature condition shall
be recorded by means of an automatic data recorder.
Test acceptance criteria: The carbon contact strip shall remain fit for purpose. The contact
strip shall remain in accordance with drawing at room temperature.
5.2.3 Test for flexural characteristic of the carbon contact strip
5.2.3.1 General
The test aims to determine the flexural characteristic of the carbon contact strip at room
temperature.
5.2.3.2 Test method
The flexural characteristic is determined by three point bending of the complete contact strip
when supported at each end of the strip along the longitudinal centreline of the contact strip
and loaded vertically at the centre. The force shall be gradually applied until permanent
deformation is recorded on a force-deflection chart. The effective stiffness shall be
determined from the results of the test and the applied force at which permanent deformation
is recorded.
62499 © IEC:2008 – 9 –
5.2.4 Test for shear strength of the contact strip
5.2.4.1 General
Definition of shear strength: Τ = F / A (N/mm )
s s
This test shall demonstrate that the adhesion between carbon and supporting structure meets
the minimum shear strength criteria at room temperature, at specified temperatures (criteria
specified by the manufacturer) and thermal fatigue. The shear strength at failure of the
specimen at room temperature shall exceed a minimum acceptable value or result in failure of
the parent carbon material alone.
5.2.4.2 Test method
5.2.4.2.1 Test at room temperature
Samples of the contact strip material shall be prepared in accordance with Figure 4:

30 mm
IEC  2194/08
Key
1 carrier
2 carbon
Figure 4 – Preparation of samples
A minimum of 3 samples shall be prepared from a production contact strip and shall include
each end of the contact strip and the centre. Each sample shall be prepared to a preferable
length of 30 mm. Each sample shall be installed in a suitable fixture (see Figure 5) in order
that the applied shear force F is guided directly into the interface defined as area of adhesion
s
A between carrier and carbon (see Figure 6).The force of failure of the sample shall be
recorded. The shear strength shall be determined by calculation of Τ
.
s
Test acceptance criterion: The minimum calculated shear strength shall be 5 N/mm .

– 10 – 62499 © IEC:2008
IEC  2195/08
Key
1 sledge
2 metal pins
3 test specimen
Figure 5 – Example of suitable fixture for testing shear strength
of carbon contact strip
IEC  2196/08
Key
1 carrier
2 carbon
3 force
Figure 6 – Example of testing configuration of shear strength test

62499 © IEC:2008 – 11 –
5.2.4.2.2 Test at specified temperature
Test specimens shall be prepared in accordance with 5.2.4.2.1. Specimens shall be cooled /
heated to –40 °C, 100 °C, 200 °C, 250 °C and the steady state temperature recorded in test
5.2.1 whether it is greater or lower than 250 °C. The temperature shall be measured at the
retention interface of the carbon and supporting structure. It shall be verified that the
temperature of the monitoring point is representative of temperature at the interface and
maintained during the test. The force of failure of each sample shall be recorded. The
characteristics of Τ with temperature shall be provided.
s
5.2.4.2.3 Thermal fatigue test
The contact strip used in 5.2.1 shall be thermally cycled from room temperature to the
maximum temperature achieved in 5.2.1.2 for 100 cycles. The electrical resistance shall be
measured before and after the test (see 5.2.7). The shear strength of the contact strip shall
be measured at the conclusion of the test by taking samples from the heated region.
Test acceptance criteria: It shall be demonstrated that the electrical resistance and method of
attachment of carbon to the carrier have not deteriorated during the test.
5.2.5 Test of autodrop detection sensor integral with contact strips
5.2.5.1 General
The following tests shall demonstrate the sealing integrity of the contact strips, the flow
continuity of the detection sensor and the operation of the detection sensor.
NOTE The tests are applicable only to contact strips that are equipped with a channel at the base of the carbon
as a sensing device.
5.2.5.2 Test method
5.2.5.2.1 Sealing integrity
The carbon contact strip autodrop detection sensor shall be inflated for a minimum of 10 s at
maximum operating pressure of the automatic dropping device (ADD). The maximum
operating pressure shall be specified by the manufacturer and be agreed by the customer; a
pressure of 10 bar is suggested. The air leakage rate shall be measured and demonstrated at
room temperature. Maximum operating pressure shall be applied to the contact strip and the
leakage rate shall be measured using a flow meter. Alternative methods of measurement are
acceptable where it can be demonstrated that they equate to the above leakage rate at
maximum operating pressure.
Test acceptance criterion: The leakage rate shall not exceed 0,1 l/min.
5.2.5.2.2 Temperature test
The carbon contact strip, tested under 5.2.2, where fitted with an autodrop detection sensor,
shall be inflated during the test described in 5.2.2 to the maximum operating pressure of the
automatic dropping device as specified by the manufacturer and be agreed by the customer (a
pressure of 10 bar is suggested) and the sealing integrity during this test shall be
continuously monitored.
Test acceptance criterion: The leakage rate shall not exceed 0,1 l/min.
5.2.5.2.3 Flow continuity
A flow meter shall be connected between the air supply and the contact strip. The supply shall
be inflated to a minimum operating pressure of the autodrop system as specified by the
manufacturer and be agreed by the customer (a pressure of 5 bar is suggested) and the
blanking plug sealing the autodrop sensing system shall be removed.

– 12 – 62499 © IEC:2008
Test acceptance criterion: The flow rate shall be recorded and shall exceed the minimum ADD
requirement.
NOTE See also 4.9 of IEC 60494-1.
5.2.5.2.4 Impact function of the autodrop detection sensor
5.2.5.2.4.1 General
The test shall demonstrate the operation of the autodrop detection sensor by impacting the
contact strip and causing a severe failure of the carbon material.
5.2.5.2.4.2 Test method
The carbon contact strip shall be supported at the interface between the pantograph and
carbon carrier at a height to allow the striking point of the pin to be in line with the maximum
wear line of the collector at mid span of the collector strip (example Figure 7). An air supply
and monitoring equipment shall be connected and the system shall be inflated to the minimum
operating pressure (Figure 8). The mass shall be retracted to a height h to provide sufficient
energy to cause a successful operation of the autodrop detection sensor with one strike, or to
an energy level as defined in the customer specification. In addition also a linear impact
method producing the equivalent energy level defined by the customer is permissible. The
energy shall be derived from the following formula:
Energy (Joules) = Mass m (kg) × gravity g × height h (m)
Test acceptance criteria: Successful autodrop operation shall be demonstrated and the
energy level recorded.
h
IEC  2197/08
Key
1 typical length of pendulum 1 m
2 typical striking pin contact diameter 13 mm
3 clamp
4 carrier
5 carbon
Figure 7 – Typical impact test device

62499 © IEC:2008 – 13 –
1 1
IEC  2198/08
Key
1 clamps at normal working position
2 carbon
3 air supply
4 on/off valve
5 flow meter
6 pneumatic tube with appropriate length and size
7 pressure gauge
Figure 8 – Air supply and monitoring equipment
5.2.6 Test of mechanical fatigue resistance of the carbon contact strip
5.2.6.1 General
This test shall demonstrate that the structural integrity of the assembly will not deteriorate in
service.
5.2.6.2 Test method
The carbon contact strip shall be supported at the interface between the pantograph and the
carbon carrier. A sinusoidal varying load including a random frequency sweep shall be applied
vertically downward on the carbon at the mid point or the maximum distance from the
mechanical support of the contact strip. The carbon contact strip shall be subjected to
cycles at a minimum frequency of 0,5 Hz, with a vertically applied load equivalent to
1,2 × 10
twice the static contact force applied by the pantograph to a single contact strip. The
maximum load generated shall be greater than 150 N and the vertical displacement shall be
at least 4 mm. A minimum of 10 million cycles shall be completed and shall include random
frequency sweep.
Test acceptance criterion: No structural deterioration of the contact strip shall be observed.
5.2.7 Test of the electrical resistance of the contact strip
5.2.7.1 General
This test shall demonstrate the electrical conductivity (or resistance) from the carbon surface
to the supporting structure and can be used to demonstrate consistent manufacture.

– 14 – 62499 © IEC:2008
5.2.7.2 Test method
The resistance shall be measured by using a tool which incorporates contact points for the
transmission of current and monitoring of voltage drop (see Figure 9). The tool shall be
applied with repeatable force to test locations at a maximum distance of 10 cm along the
length of the contact strip.
At each application a constant DC current of minimum 1 A shall be applied and the mV-drop
at the location of current application shall be recorded (see Figure 10).
Test acceptance criterion: Resistances shall be within the manufacturer’s declared resistance
limits for the carbon contact strip.

+
–
IEC  2199/08
Key
1 carrier
2 carbon
3 contact points for the transmission of current
4 mV meter
Figure 9 – Test of electrical transfer resistance from the carbon contact surface
to the supporting structure
62499 © IEC:2008 – 15 –
DC
1 1
IEC  2200/08
Key
1 contact points for the transmission of current
2 mV meter
Figure 10 – Connection scheme for test of electrical resistance

– 16 – 62499 © IEC:2008
Annex A
(normative)
List of tests
Table A.1 – Catalogue of tests
Clause Routine Type test
test
5.2.1 Tests for the temperature characteristic of the carbon contact strip under X
rated current loading
5.2.2 Test for deflection and extension of the carbon contact strip under X
extremes of temperature
5.2.3 Test for flexural characteristic of the carbon contact strip X
5.2.4 Test for shear strength of the carbon contact strip X
5.2.5.2.1 Sealing integrity X X
5.2.5.2.2 Temperature test X
5.2.5.2.3 Flow continuity X X
5.2.5.2.4 Impact function of the autodrop detection sensor X
5.2.6 Test of mechanical fatigue resistance of the carbon contact strip X
5.2.7 Test of the electrical resistance of the carbon contact strip X X

62499 © IEC:2008 – 17 –
Annex B
(informative)
Parameters to be specified by the customer

Subclause
– Replacement of routine tests with sampling tests may be agreed 5.1.2
– Customer to define the maximum operating pressure of the auto
...