Rowe Hankins - Product Guide

Rowe Hankins New Product Guide

Efficient - Innovative - Safe

Introduction Rowe Hankins Ltd specialises in innovative on-train and trackside safety products and components to the world’s railways; focusing on the design and manufacture of components used within safety critical systems and the world-wide distribution of electro-mechanical products for railways.

For over a quarter of a century RHC Ltd has been working closely with rolling stock manufacturers, train operating companies, track owners and infrastructure contractors.

In addition to manufacturing, the company has significant workshop facilities for the re-engineering of circuit breakers, contactors and other electro-mechanical devices to extend their service life. This capability is backed by test facilities including a high voltage test unit to certify product performance before shipping.

Rowe Hankins LTD’s own products include: speed sensors, current monitoring products, intelligent wheel flange lubrication and earth leakage detection units. Extensive in house design, prototype and test facilities ensure the highest quality.

With a global reputation for quality, reliability and innovation, Rowe Hankins' experienced engineers have a long and successful track record giving the highest possible level of service to rail projects in Europe, Australia, Russia, the USA and beyond.

Rowe Hankins Ltd also distributes with full technical support products from leading rail industry suppliers, including: Hydraulic-Magnetic circuit breakers from Eaton Heinemann, OTMR’s from HaslerRail and DC Power supplies.

Based in the Manchester headquarters since 1986 all products and services are manufactured and distributed.

Engineering Rowe Hankins professional engineers have worked in the rail industry for over 30 years and so have the experience to meet the requirements demanded by our customers and the Safety Authority.

Industry trained engineers to give you the highest possible level of service.

We work to the V Project Structure and utilise the IRIS standards to develop a product from design through to sale, working closely with the customer throughout the product development path. From the conceptual, design stage through to the after-sales maintenance phase, RHL will ensure that the level of work undertaken and the documentation provided will help our customers maintain or receive acceptance and approval from the Safety Authority.

Rowe Hankins Ltd believes there is a need to go ‘Beyond the Solution’ and fully understands the requirements of the customer, the customer’s customer, the application and the industry. Through offering consultation, design, development, engineering, manufacturing, maintenance, testing and repair of products, maintained by high levels of personal before, during and after sales service to ensure the best quality of service.

BENEFITS - Project management ensures fast turnaround with minimal disruption and down-time costs - Both expertise and experience in working with rolling stock manufacturers, TOC’s and train owners - Consultation, development and designs are available directly from Rowe Hankins engineers - Pre-production development reports are available for technical and economic solutions - Extensive testing to customer needs - Bespoke speed sensing solutions from our experienced engineers in speed sensor technology and applications - Electro-mechanical product expertise and knowledge - Installation supervision - Professional design and engineering support to find solutions to obsolete parts of a product or offering bespoke or alternative solutions

RCBO Residual Circuit Breaker Overload Designed for harsh environments – industrial and rail traction – the Rowe Hankins RCBO uses the industry proven Eaton® AMR series circuit breaker with an integrated current sensor.

2 POLE SERIES 373 & 4 POLE SERIES 368

FEATURES

BENEFITS

The circuit uses a current transformer to measure AC current imbalance.

- Our RCBO range uses AC residual current, and trip levels are typically between 30mA, 100mA and 300mA

Tripping characteristics:

The signal is amplified, rectified and then passed to a time delay circuit. If the signal is present after the delay then a solid state switch energises the supply circuit breaker trip coil.

Options for either a fixed time delay or an inverse time delay trip characteristics can be specified. Trip currents can be specified for factory setting at levels between 5 and 300mA (Trips levels up to 2A are possible on a 4 pole series).

A unit with a trip level of 5mA is specifically suited for the American market to meet the requirements of the ‘National Electrical Code NFPA 70’.

A wide range of time delays can be specified and set during manufacture.

The detector circuit power supply is derived from the ac supply.

A test signal can be injected through the current transformer from a test button to confirm correct operation.

- A range of various trip characteristics are available: instantaneous fixed time delay and inverse time delay - Fitted with a ‘test button’ to check the circuit breakers trip setting when an appropriate residual current fault is generated internally - Electrical connections to the unit are via M6 terminals, auxiliary contacts can be used to control and monitor the state of the circuit breaker

- Inverse time curve – the operating time of the RCBO is reduced as the residual current increases - Fived time delay – the units are tolerant of traction auxiliary supply functions

4 POLE DIMENSIONS

2 POLE DIMENSIONS

Speed Sensors Safety critical multi-channel sensors measure speed and direction, designed to operate in harsh environments and against a ferromagnetic steel target wheel.

For most applications the speed sensors are designed to work against a ferromagnetic steel target wheel by using Hall Effect sensor technology.

BENEFITS

Sensors can however be designed for magnetic target wheels with alternating north & south poles. Operating air air gap can be up to 4mm but is determined by type of sensor and target wheel profile which for ferromagnetic targets are typically a spur gear profile.

- Various signal output types

The speed sensor can have single, dual or multiple output channels of which specific channel(s) can be isolated to be powered from a different power supply. Output channel drive circuits are available as open collector, supply tracking, push-pull or 2-wire. See table opposite for generic technical details.

Connecting screened cable and connectors are selected to meet customer requirements as well as relevant fire & smoke certification.

- Designed to meet harsh rail environment

- Single, Dual or multi-pair outputs - Capable of measuring from 0 to 20kHz - Reverse supply voltage protected - Stainless steel housing in various styles - Various terminal connections or connectors - High reliability - Cost effective solution for speed measurement

ELECTRICAL Sensor output type:

Open Collector

Supply Tracking

Power supply Vs:

10V d.c. to 30V d.c. (reverse supply polarity protected)

Current consumption:

≤ 12mA for single channel, ≤36mA for 2-4 channel (without load)

Insulation resistance and test:

Insulation resistance > 100MOhm Flash test @ 600Vrms, 50Hz

Maximum output source current:

n/a

14mA @ Vs=30V

20mA

16mA

Maximum output sink current:

20mA

20mA

20mA

n/a

Number of signal outputs:

1 to 4

Output waveform:

Square wave

Signal output low voltage:

Vs ≤1.0V @20mA

Vs ≤1.0V @20mA

Vs ≤1.8V @20mA

n/a

Signal output high voltage:

n/a

(Vs/2k2+RL) * RL

> Vs -2V @20mA

n/a

Signal output low current:

n/a

n/a

n/a

4-8mA

Signal output high current:

n/a

n/a

n/a

12-16mA

Signal output frequency:

0 to 20 kHz

Phase displacement (for 2 signal pairs):

90° +/- 45° (target & alignment dependant)

Duty cycle:

30% – 70% (target & alignment dependant)

Electromagnetic compatibility (EMC):

EN 50121-3-2

Cable screen termination at sensor end:

According to customer requirements

Cable (screened):

2 to 8 core , Low smoke, Zero Halogen

Conduit for cable protection (if req.):

Low smoke, Zero Halogen

Connector (if required):

Typically MIL-C5015 Bayonet

MECHANICAL Air gap:

Typically 1.0 ± 0.5mm (target dependant)

Ambient temperature range:

-40°C to 120°C

Thermal shock:

+/- 35°C over 30 seconds

Relative humidity:

0 - 98% condensing

Protection class (IEC60529):

IP67

Impervious to:

Oil mist, salt spray, conductive dust

Shock and vibration:

EN 61373 category 3

Sensor housing material:

Stainless steel, grade SAE 30303

Push-Pull

2-wire

NIC The Non Intrustive Current Monitor is used in condition monitoring systems, allowing engineers to ‘fix before failure’.

For trackside application to assist Network Rail’s preventative maintenance program, monitoring currents (AC and DC) in rail signalling equipment for potential problems so repairs are done prior to significant failure and rail service delays.

FEATURES

BENEFITS

- Non-contact measurement of dc currents up to ±600mA

- Enables significant reduction in manual routine inspection

- 4 to 20mA current output

- Ability to ‘fix before failure’

- Current Trip with relay output

- Network Rail and SNCF approved

The NIC is used as part of the preventative maintenance systems on trackside applications. If the signal received from the NIC via the associated data logger to the programme output highlights the primary current variations are outside the normal limits, then it indicates there is a potential problem.

- LED trip indicator

- Intelligent Infrastructure initiative for remote condition monitoring and proactive maintenance

This is done when the cable carrying the current to be monitored is passed through the hole in the side of the case.

Internally it passes through a current transducer which outputs a voltage to the rectifier stage. Following full wave rectification the signal passes through a low pass filter, the output of which connects to the 4 to 20mA current output stage. (Note the full way rectification only applies to units for bipolar primary input current).

- Network Rail Approved

A comparator detects a desired trip level and the output is available as a relay contact output. An internal power supply is used to convert the 24V dc supply input to power the transducer and signal conditioning circuits.

- 24V DC power supply - Supply Reverse Polarity protection - DIN rail mounting - Unipolar versions also available

MECHANICAL DATA Value

Units

Width

22.5

mm

Depth

60.5

mm

Height

98

mm

Primary cable hole diameter

11

mm

Material

Polyamide

Mass

110

Notes

Case – DIN Rail

g

Maximum

ELECTRICAL DATA Value

Units

Notes

± 100

mA

Type 1

± 200

mA

Type 2

± 400

mA

Type 4

± 600

mA

Type 6

± 600

mA

Type 6a.

This is unipolar monitor.

at Ip=0

4

mA

at Ip=Ipmax

20

mA

Load resistance max

500

ohms

Trip Level (optional)

5 to 90% of Ipmax

%

Hysteresis

30

%

Trip LED

Red

Primary Current Ipmax

Output Current

Relay Output (optional)

Factory set

Only available if trip level set

Voltage

110V dc max

V

Current

500 mA max

mA

Volts

24V dc ±10%

V

Current

< 100mA mA

mA

@20mA load

Power on LED

Green

Frequency Response

DC to 40Hz DC to 5Hz (Type 6a)

Hz

3dB

Step response

50ms typical

ms

To 90%

Accuracy

±2

%

Operating temperature

-20 to +85

ºC

Signal

Terminal

Notes

+24V

E

0V

D

Output O/P+

B

Output O/P-

A

Relay Output N/O1

F

Connections only available if unit has trip setting

Relay Output N/O2

C

Connections only available if unit has trip setting

Primary Current

N/A

Cable passed through side hole

Resistive load

Power Supply

ELECTRICAL CONNECTIONS

Split-Core NIC The Non-Intrusive Split-Core current monitor is used in rail condition monitoring systems, allowing engineers to fix the problem before failure. The split-core Nic was designed for trackside application to assist Network Rail’s preventative maintenance program.

If the signal received from the Split-Core Nic via the associated data logger, the programme output highlights that the primary current variations are outside the normal limits. Then this will indicate that there is a potential problem.

The Split-Core NIC’s aperture can be opened and closed via a jaw latch locking system. The on board green LED indicates the unit is powered up and the red LED indicates that the primary current has reached the defined trip level. This allows installation engineers to see real time working functions. If it’s safe to do so, the Split-Core NIC can be n be installed without being equipment being monitored or shut down.

The cable carrying the current passes through a current transducer which outputs a voltage to the rectifier stage.

Following full wave rectification the signal passes through a low pass filter, the output of which connects to the 4 to 20mA current output stage; with the

ability to drive loads of 50-500ohms. The comparator detects a desired trip level and the output is available as a relay contact output. An internal power supply is used to convert the 24V dc supply input to power the transducer and signal conditioning circuits. An option for a current trip level can be provided, the output being a set of voltage free relay contacts The Split-Core NIC has the added advantage of its retro-fit installation. It allows the unit to be clamped around the cable without any circuit interference.

This means there will be no interference (to e.g. any circuits nearby or signalling systems), so the rail network can continue to run safely with no costly down time during installation of the conditional monitoring system.

It has been designed in accordance with problems caused by Network Rail’s noise by overhead lines. With added features being its “Fluxgate Sensing Technology” that is very sensitive to magnetic fields; making it more sensitive than conventional sensors; meaning a greater performance and operation over temperature ranges.

FEATURES - Non-contact measurement of AC/DC currents up to ± 600 mA - 4 to 20 mA current output - Current trip with relay output - LED trip indicator - 24 V DC power supply - Supply reverse polarity protection - DIN rail or panel mounting - The product is RoHS and WEEE Compliant

BENEFITS - No electrical shutdown of monitored equipment required for installation removal - Designed to meet Network Rail and SNCF approval - Ability for equipment to be “fixed before failure” - Intelligent infrastructure initative for remote condition monitoring and proactive maintenance

ELECTRICAL CHARACTERISTICS Measuring Ranges (lp)

600 mA

400 mA

200 mA

100 mA

Bipolar

Available

Available

Available

Available

Unipolar

Available 4 mA ± 0.15 mA

4 mA ± 0.3 mA

4 mA ± 0.6 mA

Output Zero Offset Zero Offset, after Overload (2–20 A) Zero Offset, after Overload (20–300 A)

DC Accuracy (at +25°C)

lout

4 mA ± 0.1 mA

lp lout

1 mA / A 27 μA / A

40 μA / A

80 μA / A

lp lout

< 25 mA < 0.67 mA

< 1 mA

lp lout

< 2 mA

< 4 mA

± 1% of reading ± 0.25 mA ± 1% of reading ± 6.75 µA

± 1% of reading ± 10 µA

± 1% of reading ± 20 µA

Output Sensitivity

: 4 mA = 0 A; 20 mA = Ip mA

Linearity

: ± 0.2%

Resolution

: ± 0.2 mA (Ip)

di/dt Response (10 – 90 % 0 - Ip mA)

: < 150 ms

Load Impedance

: 50 – 500 Ω

Frequency Bandwidth

: 40 Hz (-3 dB)

Power Supply (Reverse Polarity Protected)

: 24 V DC Nominal (18 – 36 V DC)

Current Consumption (inclusive of Relay Current)

: 50 mA + output current

Power On LED

: Green

Trip LED

: Red

Trip Hysteresis

: Nominally 30 %

Relay Type

: Normally Open

CONNECTOR PIN

FUNCTION

1

N/O-1

2

NC

3

O/P -

4

0V

5

N/O-2

6

NC

7

OP +

8

+ 24 V

Height

100.4mm (When fitted to Din Rail)

Height

105.8mm (Inc. Panel Mount)

Width 65.5mm Width

160 μA / A

100.5mm (Inc. Screw Plate)

± 1% of reading ± 40 µA

iWFL Intelligent Wheel Flange Lubrication To extend rail and wheel life by geographical location based dispensing of flange lubricants and top of rail friction modifiers with IWFL. IWFL is an on-board system dispensing system.

The iWFL FALCON unit controls wheel flange lubrication and application equipment on rail vehicles.

The present alternative methods of application do not promote effective use of lube exactly when and where it is required most or not at all. Thus, the benefits are restricted and the cost over-stated. iWFL has been de-signed to apply lube exactly when and where it is required and in the right amounts, enabling it to be techni-cally effective and economic.

The Rowe Hankins grease spraying systems uses air, under pressure, to drive the air/grease down pipes to each dispensing nozzle. At the nozzle the air

atomises the grease into a precisely targeted spray. Using iWFL . It is possible to specify varying levels of distribution control by time, distance, bend radius and location. The Solid Lubricant Stick systems use spring loaded cartridges to make permanent contact with the wheel’s flange. These cartridges have to be individually replenished when they’re mostly empty, making them non-environmentally friendly nor cost effective. iWFL is a fully approved on-train Lubrication system that can be fitted to both new and existing roll-ing stock. iWFL’s FALCON (Flange Area Lubrication Controller) unit directs the wheel flange lubrica-tion equipment using the latest

inertial and GPS senor technology.

The research shows that an effective flange lubrication system will extend wheel tread life by a fac-tor of 5-6 and reduce rail wear by a factor of 3-5 when compared with a non-lubricated network, cutting down not only waste but also the carbon emissions as less replacement parts are needed.

The iWFL system is relatively simple to install. It is an under-train application and can be a retro-fitted to the vehicle.

Using the tram or train’s existing (or a dedicated) antenna for GPS signals means there is a minimum of disruption to the train infrastructure.

FEATURES

BENEFITS

- Interface to train management system, interface to track balises, interface to GPS antenna

- Noise reduction

- Dispense of top of rail friction modifier and flange/back of flange lubricant

- Fuel use reduction

- Left/right and front/back individual control of dispensing nozzles

- Corrugation reduction

- Derailment risk reduction - Rolling contact fatigue reduction

- Frugal use of the TORFM and flange lubricants (re-configurable)

- Track side lubricator reduction

- Standalone/fall-back inertial (YAW, Acceleration and distance) based operation mode.

- Depot based refilling

- Track lateral force reduction

- No impairment of braking safety.

COST BENEFIT OF USING INTELLIGENT WHEEL FLANGE LUBRICATION Description

Stick Lubrication

Rowe Hankins iWFL

Distance until wheels have to be reprofiled

57,000 km

85,625 km

Frequency of refilling per year

25 to 30

6 to 9

Track benefits

Life x 2?

Life x 2 plus?

Lubricant usage

Continuous

Intelligent conditional dispensing

Intelligent wheel flange lubrication offers a 50% life extension when compared to existing technologies

Circuit Breakers Rowe Hankins Ltd is a global traction MCB specialist and has been supplying hydraulic-magnetic circuit breakers to the rail industry since 1986. Hydraulicmagnetic circuit breakers offer precise, specification assured, nuisance-fre Tolerant of the shock and vibration so common on rolling stock, they are unaffected by high in-rush currents and will only trip at their rated capacity.

They can be specified with differing time delay curves to compensate for electrical anomalies. There are many options available to permit customisation to the application including integrated auxiliary switches, alarms, remote off indicators and illuminated rocker.

The accurate and efficient protection offered by Rowe Hankins products ensures continuous and steady operation of Uninterruptible Power Supplies (UPS) units.

The magnetic time-delay circuit breaker operates on the solenoid principle where a movable core held with a spring, in a tube, and damped with a fluid, may be moved by the magnetic field of a series coil. As the core moves toward a pole piece, the reluctance of the magnetic circuit containing the armature is reduced. The armature is then attracted, causing the mechanism to trip and open the contacts on an overload or fault condition.

All Rowe Hankins circuit protectors and circuit breakers are available in many mechanical and electrical configurations to provide maximum versatility for the designer.

CIRCUIT BREAKERS FEATURES - UL1077, TÜV, UL489A approved - Designed to fit in a “1RU” application - 5000 AIC (80VDC), 2000 AIC (250VAC) interrupt capacity

Ambient Operation Operates normally in temperatures between –40° C and +85°C. Insulation Resistance Not less than 100 megaohms at 500Vdc.

- Series or mid-trip with auxiliary switch alarm options

Dielectric Strength Shall withstand AC voltage 60 Hz, for 60 seconds between all electrically isolated terminals as described below.

- Various delays including motor start

- Series, switch only : 3,750 VAC

- 1 to 2 poles, multiple termination options

- Auxiliary switches : 600 VAC

DELAY CURVES & SPECIFICATIONS

- Series w/ auxiliary switch : 3,750 between main circuit breaker terminal and auxiliary switch terminal

DC, 50/60Hz Delay Curves (typ) A choice of delays is offered for DC and 50/60Hz applications. Delays 59 and 69 provide fast-acting, instantaneous trip and are often used to protect sensitive electronic equipment (not recommended where known inrush exists). Delays 51 and 61 have a short delay for general purpose applications. Delays 52 and 62 are long enough to start certain types of motors and most transformer and capacitor loads.

Trip Free Will trip open on overload, even when forcibly held on. This prevents operator from damaging the circuit by holding handle in the ON position.

Trip Indication The operating handle moves forcibly and positively to the OFF position on overload.

Shock Shall not trip when tested per MILSTD-202, method 213, test condition 1 with 100% rated current applied to delayed units, except 90% current in plane 4, (i.e. handle down).

Instantaneous units shall have 80% rated current applied in all planes.

Vibration Shall not trip when vibrated per MILSTD-202, method 204, test condition A with 100% rated current applied to delayed units and 80% rated current to instantaneous units.

Endurance In many applications contact wear due to the electrical load determines unit life.

At maximum electrical ratings, the IAR/ IUR/IER/CUR/CER can perform 10,000 operations at rated current and voltage at a maximum rate of 6 operations per minute.

Distribution Products for Rail

RAIL SPECIALIST FOR CIRCUIT PROTECTION

ON-TRAIN MONITORING RECORDERS – OTMR

FEATURES AND BENEFITS

FEATURES AND BENEFITS

- Uniform tripping characteristics -40°C to +85°C

- ETCS/national data combined evaluation – a drawback of current evaluation tools is there is no combined evaluation of ETCS and national data. Users have to purchase two separate programs

- Tripping point remains constant across full range - No de-rating factor - Breakers and cabling - Protects both cables and equipment - Shock and vibration resistant – avoids nuisance tripping - Hot-pluggable version – no need to shut down system - No extra space needed for auxiliary / alarm contact switch or additional voltage coil - No over-sizing required – reduces cost - RoHS compliance - Expert designers, in-house automation, rapid prototyping and advanced test labs - Proven track record supporting high volume manufacturing - 24/7 engineering and support teams, located where your customers build products

- With TELOC EVA2 users can choose to evaluate ETCS or national data only, or combine the evaluations - GPS tracking on a map - evaluating data with a graph can be irritating and tedious. Hasler has developed a GPS-tracking function and, if the vehicle has a GPS system, positioning data can be recorded by the TELOC and the information displayed in a map window in the evaluation screen - Voice and Front View playback – to complete the evaluation, or for carrying out incident investigation, front view and voice data can be evaluated if the vehicle is equipped with a Hasler Voice Box

HIGH VOLTAGE SWITCHGEAR FEATURES AND BENEFITS - Safety with a high insulation level: power frequency withstands voltage up to 15kV - Industrial capability and facilities enabling production of large series - Range of contactors up to 1,500A and 4,000V AC/DC with electromagnetic or electro-pneumatic control - Proven worldwide experience and acceptance - Withstands voltage up to 10 kV - Heavy duty operational frequency (C3) guarantees a high level of performance whatever the application - Long life time of the product and low maintenance level: up to 500,000 operations - Strong competencies to provide innovative solutions, for example, protective enclosures for vehicle roof or under-frame mounting

- Server-solution – data could be stored in several locations, using up memory and resulting in time-consuming searches - TELOC EVA2 is a server-oriented program with central data storage in one place and data access from just about anywhere

CURRENT TRANSDUCERS FEATURES AND BENEFITS - Reliability: products come with a 5 year warranty, in order to deliver quality and on our commitment to provide innovative solutions - Responsiveness: deal with specific needs, expectations and priorities Innovative solutions - LEM is known within industry for its innovative technology and application know-how

Global Customer Supply

Efficient - Innovative - Safe Rowe Hankins Ltd Power House Parker Street Bury Lancashire BL9 0RJ

Telephone (UK): 0161 765 3000 Telephone (International): +44 161 765 3000 Fax (UK): 0161 705 2900 Fax (International): +44 161 705 2900 info@rowehankins.com www.rowehankins.com