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