SIST EN 15611:2020
(Main)Railway applications - Braking - Relay valves
Railway applications - Braking - Relay valves
This document is applicable to relay valves designated to control the brake cylinder pressure of compressed air brakes fitted to railway vehicles, in association with an air brake distributor valve or other control device. It covers one stage relay valves and relay valves adjusting the brake cylinder pressure in response to a change in vehicle speed or load that is either continuously variable or in two or more stages, i.e. empty – loaded.
Relay valves operating with other pressures, in particular the brake pipe pressure, are not included.
This document specifies the requirements for the design, manufacture and testing of relay valves.
Bahnanwendungen - Bremse - Relaisventile
Dieses Dokument gilt für Relaisventile, die zur Steuerung des Bremszylinderdruckes von Druckluftbremsen in Eisenbahnfahrzeugen in Verbindung mit einem Druckluftbremsensteuerventil oder einem anderen Steuergerät bestimmt sind. Es umfasst einstufige Relaisventile und Relaisventile, die den Bremszylinderdruck in Abhängigkeit von einer Änderung der Fahrzeuggeschwindigkeit oder -last, die entweder stufenlos oder in zwei oder mehr Stufen, d. h. leer - beladen, variabel ist, anpassen.
Relaisventile, die mit anderen Betriebsdrücken, insbesondere dem Druck in der Hauptluftleitung, arbeiten, sind hierin nicht erfasst.
In diesem Dokument werden die Anforderungen für die Konstruktion, die Herstellung und die Prüfung von Relaisventilen festgelegt.
Applications ferroviaires - Freinage - Relais pneumatiques
Le présent document s'applique aux relais pneumatiques conçus pour commander la pression au cylindre de frein des freins à air comprimé montés sur des véhicules ferroviaires, conjointement avec un distributeur de frein à air ou un autre dispositif de commande. Il s'applique aux relais pneumatiques à un étage de pression et aux relais pneumatiques qui régulent la pression au cylindre de frein en fonction des variations de la vitesse ou de la charge du véhicule, soit de manière continue, soit par deux étages de pression ou plus, comme les relais vide/chargé.
Les relais pneumatiques fonctionnant avec d'autres pressions, notamment la pression de conduite générale, ne sont pas inclus.
Le présent document spécifie les exigences relatives à la conception, à la fabrication et aux essais des relais pneumatiques.
Železniške naprave - Zavore - Ventili za kontrolo tlaka
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 15611:2020
01-junij-2020
Nadomešča:
SIST EN 15611:2009+A1:2011
Železniške naprave - Zavore - Ventili za kontrolo tlaka
Railway applications - Braking - Relay valves
Bahnanwendungen - Bremse - Relaisventile
Applications ferroviaires - Freinage - Relais pneumatiques
Ta slovenski standard je istoveten z: EN 15611:2020
ICS:
23.060.99 Drugi ventili Other valves
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
SIST EN 15611:2020 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 15611:2020
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SIST EN 15611:2020
EN 15611
EUROPEAN STANDARD
NORME EUROPÉENNE
April 2020
EUROPÄISCHE NORM
ICS 45.040 Supersedes EN 15611:2008+A1:2010
English Version
Railway applications - Braking - Relay valves
Applications ferroviaires - Freinage - Relais Bahnanwendungen - Bremse - Relaisventile
pneumatiques
This European Standard was approved by CEN on 13 January 2020.
CEN 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 CEN-CENELEC Management Centre or to any CEN
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 CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15611:2020 E
worldwide for CEN national Members.
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SIST EN 15611:2020
EN 15611:2020 (E)
Contents Page
European foreword . 3
1 Scope . 4
2 Normative references . 4
3 Terms and definitions . 4
4 Symbols and abbreviations . 9
5 Design and manufacture . 9
5.1 General . 9
5.2 Functional requirements. 11
5.3 Shock and vibration . 16
5.4 Environmental conditions . 16
5.5 Compressed air quality . 18
5.6 Service life . 18
5.7 Fire behaviour . 19
5.8 External appearance . 19
5.9 Design requirements regarding pressure stress . 19
5.10 Interface . 19
6 Materials . 19
7 Type tests . 20
7.1 General . 20
7.2 Type test of an individual relay valve . 20
8 In-service assessment. 46
9 Designation. 46
10 Identification and marking . 46
Annex A (informative) In-service assessment . 47
A.1 General . 47
A.2 Test set-up and sampling . 47
A.3 Procedure. 47
A.4 Pass/fail criteria . 47
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of Directive 2008/57/EC aimed to be covered . 48
Bibliography . 50
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SIST EN 15611:2020
EN 15611:2020 (E)
European foreword
This document (EN 15611:2020) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by October 2020, and conflicting national standards shall
be withdrawn at the latest by October 2020.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights
This document supersedes EN 15611:2008+A1:2010.
Compared to the previous edition, the following changes have been made:
a) normative references have been updated;
b) terms and definitions have been revised;
c) requirements on design have been revised;
d) requirements on materials have been revised;
e) requirements on type testing have been revised;
f) requirements on in-service assessment have been revised
g) requirements on markings have been revised;
h) annexes have been revised.
This document has been prepared under a standardization request given to CEN by the European
Commission and the European Free Trade Association, and supports essential requirements of
EU Directive 2008/57/EC.
For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of
this document.
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland,
Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United
Kingdom.
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SIST EN 15611:2020
EN 15611:2020 (E)
1 Scope
This document is applicable to relay valves designated to control the brake cylinder pressure of
compressed air brakes fitted to railway vehicles, in association with an air brake distributor valve or
other control device. It covers one stage relay valves and relay valves adjusting the brake cylinder
pressure in response to a change in vehicle speed or load that is either continuously variable or in two or
more stages, i.e. empty – loaded.
Relay valves operating with other pressures, in particular the brake pipe pressure, are not included.
This document specifies the requirements for the design, manufacture and testing of relay valves.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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 14478:2017, Railway applications — Braking — Generic vocabulary
EN 15355:2019, Railway applications — Braking — Distributor valves and distributor-isolating devices
EN 15625:2008+A1:2010, Railway applications — Braking — Automatic variable load sensing devices
EN 45545-1:2013, Railway applications — Fire protection on railway vehicles — Part 1: General
EN 45545-2:2013+A1:2015, Railway applications — Fire protection on railway vehicles — Part 2:
Requirements for fire behaviour of materials and components
EN 50125-1:2014, Railway applications — Environmental conditions for equipment — Part 1: Rolling
stock and on-board equipment
EN 60721-3-5:1997, Classification of environmental conditions — Part 3: Classification of groups of
environmental parameters and their severities — Section 5: Ground vehicle installations
(IEC 60721-3-5:1997)
EN 61373:2010, Railway applications — Rolling stock equipment — Shock and vibration tests
(IEC 61373:2010)
EN ISO 228-1:2003, Pipe threads where pressure-tight joints are not made on the threads —Part 1:
Dimensions, tolerances and designation (ISO 228-1:2000)
ISO 8573-1:2010, Compressed air —Part 1: Contaminants and purity classes
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 14478:2017, EN 15355:2019
and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at http://www.iso.org/obp
4
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SIST EN 15611:2020
EN 15611:2020 (E)
3.1
relay valve
device, the main function of which is to control a pneumatic output pressure as a function of the variation
of one or more input pressures (see Figure 1)
Key
1 first input pressure
2 second input pressure
3 third input pressure
4 control signal – continuous load sensing pressure (LCP), or control signal – empty/load signal pressure (LSP),
or mechanical input (lever) or electrical input
5 auxiliary reservoir pressure, supply pressure (AR)
6 output pressure
7 relay valve
Figure 1 — Relay valve, pressures and signals
3.2
input pressure
control pressure received by the relay valve
Note 1 to entry: Pressure generally considered as being the output pressure from a distributor or a brake control
unit; sometimes referred to as pilot pressure or dummy brake cylinder pressure.
3.3
output pressure
pressure output from the relay valve, generally considered as being the brake cylinder pressure
Note 1 to entry: This pressure can also be used as the input pressure to another relay valve. The output pressure
can obtain one or more fixed levels or it can be changed continuously between a minimum and a maximum or vice
versa.
3.4
relay valve ratio
ratio of the output pressure value to input pressure value
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EN 15611:2020 (E)
3.5
control signal
signal used to change the relay valve ratio:
— received from the continuous load sensing device (LCP),
— received from empty-loaded changeover device (LSP),
— generated by the position of mechanical changeover,
— generated by other means, e.g. speed dependent
3.6
relay valve type A
relay valve with one fixed relay valve ratio, where the ratio can be less (step-down), equal or greater
(step-up) than 1
3.7
relay valve type B1
relay valve with two or more fixed relay valve ratios that can change during a brake application, where
the ratio can be less (step-down), equal or greater (step-up) than 1
Note 1 to entry: Typically, two stages “empty/load” relay valve, giving an empty (tare) or a loaded output
pressure proportional to input pressure dependant on the load signal input and used on vehicles operated in empty
or fully loaded condition. Alternatively, the ratio can be changed in function of speed.
3.8
relay valve type B2
relay valve with two or more fixed relay valve ratios that cannot change during a brake application, where
the ratio can be less (step-down), equal or greater (step-up) than 1
Note 1 to entry: Typically, two stage “empty/load” relay valve, giving an empty (tare) or a loaded output pressure
proportional to input pressure dependant on the load signal input. Blocking the relay valve ratio during brake
application is typically used to avoid frequent changeovers taking place on vehicles operated near the changeover
weight.
3.9
relay valve type C1
one stage relay valve with a continuously changeable relay valve ratio, where a load signal is used to
change the ratio
3.10
relay valve type C2
relay valve with a continuously changeable relay valve ratio, where a load signal is used to change the
ratio and with a multi-stage feature added
Note 1 to entry: Typically, a load signal is used to change the relay valve ratio and a control signal (automatic or
manual) is used to change the stage(s). The typical result is that at the same load and input pressure, in the lower
stage (e.g. P-mode, passenger train) results a lower output pressure and in a higher stage (e.g. R-mode, rapid
passenger train) this results in a higher output pressure.
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SIST EN 15611:2020
EN 15611:2020 (E)
3.11
function D for a relay valve
overlay function to relay valve type A, C1, C2 with two or more input pressures
Note 1 to entry: In this case the type of the relay valve is respectively AD, C1D and C2D.
3.12
relay valve type E
variable load relay valve with a special, non-linear characteristic, which automatically comes into
operation when the vehicle has more than a certain load
Note 1 to entry: The E type may be a combination of a C1 or C2 type and an additional functional block, or may
be a specific generic design. This function reduces (in comparison with a linear characteristic) the output pressure
for low input pressures to a certain level to limit the heat impact to the wheels during continuous braking.
3.13
sensitivity
change of input pressure causing a variation of output pressure, when the change of input pressure is in
the same direction, with no overshoot or reversal
3.14
initial sensitivity
change of input pressure, starting at 0 bar, which causes the output pressure to start increasing
(see Figure 2)
3.15
sensitivity at reversal
change of input pressure causing a variation of output pressure, when the input pressure is changing
from increasing to decreasing (see Figure 2)
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EN 15611:2020 (E)
3.16
hysteresis
difference in output pressure with the same input pressure, first rising to a value and then, having been
taken past that value, subsequently falls to the same value (see Figure 2)
Key
1 initial sensitivity
2 hysteresis
3 sensitivity at reversal
NOTE The figure is simplified for illustrative purposes, e.g. the real pressure development is not shown.
Figure 2 — Hysteresis and sensitivity
3.17
normal litre
unit of amount of a gas equal to the amount of 1 l at a pressure of 1,00 bar and at a standard temperature,
at 20 °C
Note 1 to entry: Air flow is often stated in normal litres per minute (Nl/min).
3.18
matched pair
combination of a distributor valve and one or more relay valves to achieve specific tolerances of brake
cylinder pressure and timings
Note 1 to entry: The combination is usually kept together throughout the lifetime of the components.
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SIST EN 15611:2020
EN 15611:2020 (E)
4 Symbols and abbreviations
For the purposes of this document, the symbols and abbreviations given in Table 1 apply.
Table 1 — Symbols and abbreviations
Symbol Designation Unit
p pressure bar
p
input pressure bar
i
p
output pressure bar
o
t time s
AR auxiliary reservoir pressure, supply pressure bar
BCP brake cylinder pressure bar
LCP control signal – continuous load sensing pressure bar
LSP control signal – empty/load signal pressure bar
5 Design and manufacture
5.1 General
A relay valve shall enable a distributor valve or a brake control unit to be used without any vehicle specific
modification to the distributor or the brake control unit, related to the brake cylinder volume. This
includes the independence of the brake application and release times, the inshot feature and the output
pressure development for any output (brake cylinder and piping) volume.
The use of a relay valve shall not alter any of the characteristics of the distributor and/or a brake control
unit that are not specified in this standard.
The use of a relay valve shall enable the brake cylinder pressure to be maintained between prescribed
limits. These limits may be defined by different brake modes or speed-dependent requirements or where
there is a requirement to maintain a nominal constant brake performance irrespective of load.
Table 2 below provides a description of relay valve types described in this standard in comparison to
EN 15611:2010.
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Table 2 — Relay valve types
Basic type Design Optional additional Type Type
variants function
(EN 15611:2010) (new)
adaptable by none A A
one fixed ratio of diameters of
output/input pistons
multi input for “select
— AD
pressures or adjustable
high”
by screw
adaptable by ratio can change during
B1 B1
more than one fixed
diameters of brake application
ratio of output/ input
pistons
ratio cannot change
a
or adjustable
pressures
B2 B2
during brake application
by screw
none C C1
with a multi stage
C1 C2
feature added
two input pressures for
variable load relay
D C1D
“select high”
valve
two input pressures for
“select high”
D C2D
with a multi stage
feature added
variable load relay
special nonlinear
valve with kinked
characteristic (kink E E
b
valve)
characteristics
a
A multi stage relay valve with only two stages giving output pressures corresponding to empty or laden
vehicle can be named empty/load relay valve.
b
The E type may be a combination of a C1 or C2 type and additional functional block, or may be a specific
generic design.
The adjustment range of the output pressure for adjustable by screw, adaptable by the diameter of the
piston and variable load relay valves should be from 0,50 bar to 6,00 bar.
Adjustment of the maximum output pressure of a relay valve adjustable by screw should be achieved
without changing internal parts and be accessible without dismantling the device. However, an easily
removable protective device should be installed.
For a defined adjustment of a certain spring, the setting of the stops for low and high output pressures of
a variable load relay valve should be achieved without changing internal parts and be accessible without
dismantling the device. However, an easily removable protective device should be installed.
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5.2 Functional requirements
5.2.1 General
The requirements shall be tested as given by Table 5.
5.2.2 Minimum output pressure
The specific minimum output pressure of a relay valve as response to a first brake step with an input
pressure of (0,75 ± 0,02) bar shall have a fixed value, defined by its documentation.
Figure 3 gives an example of the output pressure of a relay valve for different conditions of vehicle load.
Key
1 empty condition
2 loaded condition
3 input pressure (0,75 ± 0,02) bar
4 minimum output pressure loaded
5 minimum output pressure empty
NOTE The shown characteristic is an option.
Figure 3 — Example of the output pressure p of a relay valve (brake cylinder pressure) in
o
relation to the input pressure p for different conditions of vehicle load
i
5.2.3 Accuracy of the output pressure and changeover
5.2.3.1 General (all types)
The output pressure of the relay valve shall be within the following tolerances, related to the minimum
(empty)/maximum (loaded) figures, given by the type plate and the installation drawing of the relay
valve:
— ± 0,10 bar for nominal output pressures ≤ 3,80 bar at an input pressure of (3,80 ± 0,02) bar
(ratios ≤ 1);
— ± 0,15 bar for nominal output pressures > 3,80 bar at an input pressure of (3,80 ± 0,02) bar
(ratios > 1).
A relay valve may change from a ratio < 1 in empty to > 1 in loaded status.
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EN 15611:2020 (E)
5.2.3.2 Accuracy of the changeover of a multi-stage relay valve (types B1 and B2)
The relay valve shall be designed to changeover from the empty (low), to intermediate (if applicable),
and to the loaded (high) condition and reverse, as defined in 5.2.4, at specified values of the control signal
such as load signal pressure or load sensing pressure (LSP/LCP) or with a mechanical changeover. The
accuracy of the changeover shall be tested in accordance with 7.2.4.4 (types B1 and B2).
5.2.3.3 Accuracy of the changeover of a variable load relay valve with a multi-stage function
overlaid to the variable load brake function (types C2 and C2D)
It shall be possible at any input pressure and any load control pressure (LCP) to change from a lower to
a higher level of the output pressure or vice versa.
The ratio of the gradient of the output to the input pressures between the higher value of the output
pressure to the lower value shall be constant between first brake step and full service and within a
tolerance of ± 10 % for any load condition; this condition is related to a nominal input pressure of
3,80 bar and shall be initiated by a pneumatic or electric control signal.
The accuracy of the changeover shall be tested in accordance with 7.2.4.10 (types C2 and C2D).
5.2.3.4 Accuracy of the output pressure of a relay valve designed for two or more input pressures
(types AD, C1D and C2D)
The output pressure of the relay valve shall correspond to the highest of the input pressures. The
tolerance of the maximum output pressure values shall be ± 0,10 bar, if the nominal value is ≤ 3,80 bar
and ± 0,15 bar, if the nominal value is > 3,80 bar. In the case where two or more input pressures are
acting simultaneously, the output pressure tolerance shall be ± 0,20 bar, if the nominal value is ≤ 3,80 bar
and ± 0,30 bar, if the nominal value is > 3,80 bar.
The accuracy of the output pressure shall be tested in accordance with 7.2.4.13 (types AD, C1D and C2D).
5.2.3.5 Hysteresis of the output pressure in relation to the load control pressure (types C1, C2,
C1D, C2D)
For relay valves C1, C2 the differences of the output pressure, when load control pressure (LCP) has been
increased or decreased, shall not exceed 0,20 bar if the ratio is ≤ 1 and 0,30 bar if the ratio is > 1.
For a relay valve type C1D, C2D, the differences of the output pressure when load control pressure (LCP)
has been increased or decreased shall not exceed 0,25 bar if the ratio is ≤ 1 and 0,30 bar if the ratio is > 1.
For relay valves C1, C2, C1D, C2D in case that the quotient Delta-BCP/Delta-LCP is greater than 1, the
differences of the output pressure when load control pressure (LCP) has been increased or decreased
shall not exceed 0,30 bar if the quotient is ≤ 1 and 0,40 bar if the ratio is > 1.
The accuracy of the output pressure shall be tested in accordance with 7.2.4.7 (types C1, C2, C1D
and C2D).
5.2.4 Control signal characteristics (types B1, B2, C1, C2, C1D, C2D, E)
The design of the relay valve shall allow interaction with at least one of the following load signal types:
a) manual empty-load signal, where this signal is provided by a lever, either mounted directly on the
relay valve, or remotely operated on the vehicle to manually change from the low to the high output
pressure, or vice versa;
b) pneumatic empty/load signal, where the relay valve shall be designed to operate on receipt of the
relevant signal pressure dependent on the brake system design, as follows:
1) Where the control pressure LSP/LCP is ≤ 0,50 bar this indicates a load that is less than the
switching point and shall cause the relay valve to output its lower ratio. If LSP/LCP pressure
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EN 15611:2020 (E)
is ≥ 3,00 bar this indicates a load greater than the switching point and shall cause the relay valve
to output its higher ratio. Other switching points may be defined by the design documentation.
2) Where the changeover device is supplied from the BCP, the load signal can either be 0 bar and
shall cause relay valve to output its lower output ratio or equivalent to the brake cylinder
pressure and shall cause relay valve to output its higher ratio.
3) Where the changeover device is supplied from the AR, the load signal can either be 0 bar and
shall cause relay valve to output its lower output ratio or equivalent to the AR and shall cause
relay valve to output its higher ratio.
NOTE The signal pressure is typically supplied as a load control signal pressure (LSP) from a manually
operated pneumatic device, e.g. a changeover cock, or an automatic empty-load changeover device.
Alternatively, it is supplied as a continuous load sensing pressure (LCP).
c) variable load signal, i.e. where the load sensing pressure (LCP) comes from an automatic
continuously variable load sensing device (weighing valve) giving continuous load information,
see EN 15625:2008+A1:2010;
d) speed dependent or other control signal, where the pressure settings shall be defined by the design
documentation.
5.2.5 Enabling of a change of relay valve ratio during brake application of a relay valve of
type B1
Whilst the brakes are applied, changes of the control signal shall initiate the change of the relay valve
ratio.
Higher pressure values of the control signal may be required to achieve a change of relay valve ratio for
other than freight applications e.g. for locomotives or multiple units. In this case the pressure values of
the control signal will be higher than the values contained in 7.2.4.5 and the test in 7.2.4.5 shall be
amended to meet the requirements of the specific relay valve application.
5.2.6 Prevention of a change of relay valve ratio during brake application of a relay valve of type
B2 and a variable load relay valve, types C1, C2, C1D, C2D, E
Whilst the brakes are applied with an output pressure ≥ 1,00 bar, changes of the control signal
of ± 0,50 bar shall not initiate a change of the relay valve ratio.
5.2.7 Kinked characteristic of a variable load relay valve (type E)
A variable load relay valve with kinked characteristic may be specified for use on freight wagons with
tread brakes.
A relay valve with a kinked characteristic shall be designed to operate in association with distributor
valves compliant with EN 15355:2019, for use on tread braked wagons of greater braked weight than a
value defined by the relevant documents. The required characteristic shall reduce the output pressure
(BCP) at lo
...
SLOVENSKI STANDARD
oSIST prEN 15611:2018
01-oktober-2018
Železniške naprave - Zavore - Ventili za kontrolo tlaka
Railway applications - Braking - Relay valves
Bahnanwendungen - Bremse - Relaisventile
Applications ferroviaires - Freinage - Relais pneumatiques
Ta slovenski standard je istoveten z: prEN 15611
ICS:
23.060.99 Drugi ventili Other valves
45.040 Materiali in deli za železniško Materials and components
tehniko for railway engineering
oSIST prEN 15611:2018 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 15611:2018
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oSIST prEN 15611:2018
DRAFT
EUROPEAN STANDARD
prEN 15611
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2018
ICS 45.040 Will supersede EN 15611:2008+A1:2010
English Version
Railway applications - Braking - Relay valves
Applications ferroviaires - Freinage - Relais Bahnanwendungen - Bremse - Relaisventile
pneumatiques
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 256.
If this draft becomes a European Standard, CEN 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.
This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC
Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2018 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15611:2018 E
worldwide for CEN national Members.
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Contents Page
European foreword . 4
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Symbols and abbreviations . 10
5 Design and manufacture . 10
5.1 General . 10
5.2 Functional requirements. 11
5.2.1 General . 11
5.2.2 Minimum output pressure . 11
5.2.3 Accuracy of the output pressure and changeover . 12
5.2.4 Control signal characteristics (types B1, B2, C1, C2, C1D, C2D, E) . 13
5.2.5 Enabling of a change of relay valve ratio during brake application of a relay valve of
type B1 . 14
5.2.6 Prevention of a change of relay valve ratio during brake application of a relay valve
of type B2 and a variable load relay valve, types C1, C2, C1D, C2D, E . 14
5.2.7 Kinked characteristic of a variable load relay valve (type E) . 14
5.2.8 Interaction of a relay valve and a distributor valve . 14
5.2.9 Hysteresis. 16
5.2.10 Sensitivity . 16
5.2.11 Flow . 16
5.2.12 Tightness . 16
5.2.13 Change of relay valve ratio . 16
5.3 Shock and vibration . 17
5.4 Environmental conditions . 17
5.4.1 General . 17
5.4.2 Temperature . 17
5.4.3 Other environmental conditions . 17
5.5 Compressed air quality . 19
5.6 Service life . 19
5.7 Fire behaviour . 19
5.8 External appearance . 20
5.9 Design requirements regarding pressure stress . 20
5.10 Interface . 20
5.10.1 General . 20
5.10.2 Mechanical . 20
5.10.3 Pneumatic . 20
6 Materials . 20
7 Type tests . 20
7.1 General . 20
7.2 Type test of an individual relay valve . 21
7.2.1 Test bench for individual relay valves . 21
7.2.2 Sampling for type tests . 23
7.2.3 Test temperature and air quality . 23
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7.2.4 Procedure for type tests . 23
8 In-service assessment . 46
9 Designation . 47
10 Identification and marking . 47
Annex A (informative) In-service assessment . 48
A.1 General . 48
A.2 Test set-up and sampling . 48
A.3 Procedure . 48
A.4 Pass/fail criteria . 48
Annex ZA (informative) Relationship between this European Standard and the essential
requirements of Directive 2008/57/EC aimed to be covered . 49
Bibliography . 51
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European foreword
This document (prEN 15611:2018) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 15611:2008+A1:2010.
This document has been prepared under a standardization request given to CEN by the European
Commission and the European Free Trade Association, and supports essential requirements of
EU Directive 2008/57/EC.
For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of
this document.
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1 Scope
This document is applicable to relay valves designated to control the brake cylinder pressure of
compressed air brakes fitted to railway vehicles, in association with an air brake distributor valve or
other control device. It covers one stage relay valves and relay valves adjusting the brake cylinder
pressure in response to a change in vehicle speed or load that is either continuously variable or in two or
more stages, i.e. empty – loaded.
Relay valves operating with other pressures, in particular the brake pipe pressure, are not included.
This document specifies the requirements for the design, manufacture and testing of relay valves.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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 14478, Railway applications – Braking - Generic vocabulary
EN 15355, Railway applications – Braking - Distributor valves and distributor-isolating devices
EN 15625, Railway applications – Braking - Automatic variable load sensing devices
EN 45545-1, Railway applications - Fire protection on railway vehicles – Part 1: General
EN 45545-2, Railway applications - Fire protection on railway vehicles – Part 2: Requirements for fire
behaviour of materials and components
EN 50125-1, Railway applications - Environmental conditions for equipment – Part 1: Rolling stock and on-
board equipment
EN 60721-3-5:1997, Classification of environmental conditions – Part 3: Classification of groups of
environmental parameters and their severities – Section 5: Ground vehicle installations
(IEC 60721-3-5:1997)
EN 61373:2010, Railway applications - Rolling stock equipment - Shock and vibration tests
(IEC 61373:2010)
EN ISO 228-1, Pipe threads where pressure-tight joints are not made on the threads – Part 1: Dimensions,
tolerances and designation (ISO 228-1:2000)
ISO 8573-1:2010, Compressed air – Part 1: Contaminants and purity classes
3 Terms and definitions
For the purposes of this document, the terms and definitions given in EN 14478, EN 15355 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at http://www.iso.org/obp
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3.1
relay valve
device, the main function of which is to control a pneumatic output pressure as a function of the variation
of one or more input pressures (see Figure 1)
Key
1 first input pressure
2 second input pressure
3 third input pressure
4 control signal – continuous load sensing pressure (Lcp), or control signal – empty/load signal pressure (Lsp),
or mechanical input (lever) or electrical input
5 auxiliary reservoir pressure, supply pressure (AR)
6 output pressure
7 relay valve
Figure 1 — Relay valve, pressures and signals
3.2
input pressure
control pressure received by the relay valve
Note 1 to entry: Pressure generally considered as being the output pressure from a distributor or a brake control
unit; sometimes referred to as pilot pressure or dummy brake cylinder pressure.
3.3
output pressure
pressure output from the relay valve, generally considered as being the brake cylinder pressure
Note 1 to entry: This pressure can also be used as the input pressure to another relay valve. The output pressure
can obtain one or more fixed levels or it can be changed continuously between a minimum and a maximum or vice
versa.
3.4
relay valve ratio
ratio of the output pressure value to input pressure value
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3.5
control signal
signal used to change the relay valve ratio:
— received from the continuous load sensing device (Lcp),
— received from empty-loaded changeover device (Lsp),
— generated by the position of mechanical changeover,
— generated by other means, e.g. speed dependent
3.6
relay valve type A
relay valve with one fixed relay valve ratio, where the ratio can be less (step-down), equal or greater
(step-up) than 1
3.7
relay valve type B1
relay valve with two or more fixed relay valve ratios that can change during a brake application, where
the ratio can be less (step-down), equal or greater (step-up) than 1
Note 1 to entry: Typically two stages “empty/load” relay valve, giving an empty (tare) or a loaded output
pressure proportional to input pressure dependant on the load signal input and used on vehicles operated in empty
or fully loaded condition. Alternatively the ratio can be changed in function of speed.
3.8
relay valve type B2
relay valve with two or more fixed relay valve ratios that cannot change during a brake application, where
the ratio can be less (step-down), equal or greater (step-up) than 1
Note 1 to entry: Typically two stage “empty/load” relay valve, giving an empty (tare) or a loaded output pressure
proportional to input pressure dependant on the load signal input. Blocking the relay valve ratio during brake
application is typically used to avoid frequent changeovers taking place on vehicles operated near the changeover
weight.
3.9
relay valve type C1
one stage relay valve with a continuously changeable relay valve ratio, where a load signal is used to
change the ratio
3.10
relay valve type C2
relay valve with a continuously changeable relay valve ratio, where a load signal is used to change the
ratio and with a multi-stage feature added
Note 1 to entry: Typically a load signal is used to change the relay valve ratio and a control signal (automatic or
manual) is used to change the stage(s). The typical result is that at the same load and input pressure, in the lower
stage (e.g. P-mode, passenger train) results a lower output pressure and in a higher stage (e.g. R-mode, rapid
passenger train) this results in a higher output pressure.
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3.11
function D for a relay valve
overlay function to relay valve type A, C1, C2 with two or more input pressures
Note 1 to entry: In this case the type of the relay valve is resp. AD, C1D and C2D.
3.12
relay valve type E
variable load relay valve with a special, non-linear characteristic, which automatically comes into
operation when the vehicle has more than a certain load
Note 1 to entry: The E type may be a combination of a C1 or C2 type and an additional functional block, or may
be a specific generic design. This function reduces (in comparison with a linear characteristic) the output pressure
for low input pressures to a certain level to limit the heat impact to the wheels during continuous braking.
3.13
sensitivity
change of input pressure causing a variation of output pressure, when the change of input pressure is in
the same direction, with no overshoot or reversal
3.14
initial sensitivity
change of input pressure, starting at 0 bar which causes the output pressure to start increasing
(see Figure 2)
3.15
sensitivity at reversal
change of input pressure causing a variation of output pressure, when the input pressure is changing
from increasing to decreasing (see Figure 2)
3.16
hysteresis
difference in output pressure with the same input pressure, first rising to a value and then, having been
taken past that value, subsequently falls to the same value (see Figure 2)
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Key
1 initial sensitivity
2 hysteresis
3 sensitivity at reversal
NOTE The figure is simplified for illustrative purposes, e.g. the real pressure development is not shown.
Figure 2 — Hysteresis and sensitivity
3.17
normal litre
unit of amount of a gas equal to the amount of 1 l at a pressure of 1 atmosphere and at a standard
temperature, at 20 °C
Note 1 to entry: Air flow is often stated in normal litres per minute (Nl/min).
3.18
matched pair
combination of a distributor valve and one or more relay valves to achieve specific tolerances of brake
cylinder pressure and timings
Note 1 to entry: The combination is usually kept together throughout the lifetime of the components.
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4 Symbols and abbreviations
Table 1 — Symbols and abbreviations
Symbol Designation Unit
B
brake cylinder pressure bar
cp
Lcp control signal – continuous load sensing pressure bar
Lsp control signal – empty/load signal pressure bar
p pressure bar
p
input pressure bar
i
p
output pressure bar
o
t time s
AR auxiliary reservoir pressure, supply pressure bar
5 Design and manufacture
5.1 General
A relay valve shall enable a distributor valve or a brake control unit to be used without any vehicle specific
modification to the distributor or the brake control unit, related to the brake cylinder volume. This
includes the independence of the brake application and release times, the inshot feature and the output
pressure development for any output (brake cylinder and piping) volume.
The use of a relay valve shall not alter any of the characteristics of the distributor and/or a brake control
unit that are not specified in this standard.
The use of a relay valve shall enable the brake cylinder pressure to be maintained between prescribed
limits. These limits may be defined by different brake modes or speed-dependent requirements or where
there is a requirement to maintain a nominal constant brake performance irrespective of load.
Table 2 below provides a description of relay valve types described in this standard with the relevant
clause references.
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Table 2 — Relay valve types
Basic type Design Optional Type (EN15611–2010) Type
variants additional (new)
function
adaptable by no A A
one fixed ratio of diameters of
output/input pistons
multi input for
AD
pressures or adjustable
“select high”
by screw
ratio can change
adaptable by
during brake B1 B1
more than one fixed
diameters of
application
ratio of output/ input
pistons
ratio cannot change
a
or adjustable
pressures
during brake B2 B2
by screw
application
no C C1
with a multi stage
C1 C2
feature added
two input pressures
variable load relay
D C1D
for “select high”
valve
two input pressures
for “select high”
D C2D
with a multi stage
feature added
variable load relay
special nonlinear
valve with kinked
characteristic (kink E E
b
valve)
characteristics
a
A multi stage relay valve with only two stages giving output pressures corresponding to empty or laden
vehicle can be named empty/load relay valve.
b
The Etype may be a combination of a C1 or C2 type and additional functional block, or may be a specific
generic design.
5.2 Functional requirements
5.2.1 General
The requirements shall be tested as given by Table 5.
5.2.2 Minimum output pressure
The specific minimum output pressure of a relay valve as response to a first brake step with an input
pressure of (0,75 ± 0,02) bar shall have a fixed value, defined by its documentation.
Figure 3 gives an example of the output pressure of a relay valve for different conditions of vehicle load.
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Key
1 empty condition
2 loaded condition
3 input pressure (0,75 ± 0,02) bar
4 minimum output pressure loaded
5 minimum output pressure empty
NOTE The kinked characteristics is an option.
Figure 3 — Example of the output pressure po of a relay valve (brake cylinder pressure) in
relation to the input pressure p for different conditions of vehicle load
i
5.2.3 Accuracy of the output pressure and changeover
5.2.3.1 General (all types)
The output pressure of the relay valve shall be within the following tolerances, related to the minimum
(empty)/maximum (loaded) figures, given by the type plate and the installation drawing of the relay
valve:
— ± 0,10 bar for nominal output pressures ≤ 3,8 bar at an input pressure of (3,8 ± 0,02) bar (ratios ≤ 1);
— ± 0,15 bar for nominal output pressures > 3,8 bar at an input pressure of (3,8 ± 0,02) bar (ratios > 1).
A relay valve may change from a ratio < 1 in empty to > 1 in loaded status.
5.2.3.2 Accuracy of the changeover of a multi-stage relay valve (types B1 and B2)
The relay valve shall be designed to changeover from the empty (low), to intermediate (if applicable),
and to the loaded (high) condition and reverse, as defined in 5.2.4, at specified values of the control signal
such as load signal pressure or load sensing pressure (Lsp/Lcp) or with a mechanical changeover.The
accuracy of the changeover shall be tested in accordance with 7.2.4.4 (types B1 and B2).
5.2.3.3 Accuracy of the changeover of a variable load relay valve with a multi-stage function
overlaid to the variable load brake function (types C2 and C2D)
It shall be possible at any input pressure and any load control pressure (Lcp) to change from a lower to a
higher level of the output pressure or vice versa.
The ratio of the output to the input pressures between the higher value of the output pressure to the
lower value shall be constant between initial and full service and within a tolerance of ± 10 % for every
load condition; this condition is related to a nominal input pressure of 3,8 bar and shall be initiated by a
pneumatic or electric control signal.
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5.2.3.4 Accuracy of the output pressure of a relay valve designed for two or more input pressures
(types AD, C1D and C2D)
The output pressure of the relay valve shall correspond to the highest of the input pressures. The
tolerance of the maximum output pressure values shall be ± 0,1 bar, if the nominal value is ≤ 3,8 bar
and ± 0,15 bar, if the nominal value is > 3,8 bar. In the case where two or more input pressures are acting
simultaneously, the output pressure tolerance shall be ± 0,20 bar, if the nominal value is ≤ 3,8 bar
and ± 0,30 bar, if the nominal value is > 3,8 bar.
5.2.3.5 Accuracy of the output pressure in relation to the load control pressure (types C1, C2,
C1D, C2D)
For relay valves C1, C2 the differences of the output pressure, when load control pressure (Lcp) has been
increased or decreased, shall not exceed 0,20 bar if the ratio is ≤ 1 and 0,30 bar if the ratio is > 1.
For a relay valve type C1D, C2D, the differences when load control pressure (Lcp) has been increased or
decreased shall not exceed 0,25 bar if the ratio is ≤ 1 and 0,3 bar if the ratio is > 1.
For relay valves C1, C2, C1D, C2D in case that the quotient Delta-Bcp/Delta-Lcp is greater than 1, the
differences when load control pressure (Lcp) has been increased or decreased shall not exceed 0,3 bar if
the quotient is ≤ 1 and 0,4 bar if the ratio is > 1.
5.2.4 Control signal characteristics (types B1, B2, C1, C2, C1D, C2D, E)
The design of the relay valve shall allow interaction with at least one of the following load signal types:
a) manual empty-load signal, where this signal is provided by a lever, either mounted directly on the
relay valve, or remotely operated on the vehicle to manually change from the low to the high output
pressure, or vice versa;
b) pneumatic empty/load signal, where the relay valve shall be designed to operate on receipt of the
relevant signal pressure dependent on the brake system design, as follows:
1) Where the control pressure Lsp/Lcp is ≤ 0,5 bar this indicates a load that is less than the
switching point and shall cause the relay valve to output its lower ratio. If Lsp/Lcp pressure
is ≥ 3,0 bar this indicates a load greater than the switching point and shall cause the relay valve
to output its higher ratio. Other switching points may be defined by the design documentation.
2) Where the changeover device is supplied from the Bcp, the load signal can either be 0 bar and
shall cause relay valve to output its lower output ratio or equivalent to the brake cylinder
pressure and shall cause relay valve to output its higher ratio.
NOTE The signal pressure is typically supplied as a load control signal pressure (Lsp) from a manually operated
pneumatic device, e.g. a changeover cock, or an automatic empty-load changeover device. Alternatively it is
supplied as a continuous load sensing pressure (Lcp).
c) variable load signal, i.e. where the load sensing pressure (Lcp) comes from an automatic
continuously variable load sensing device (weighing valve) giving continuous load information,
see EN 15625;
d) speed dependent or other control signal, where the pressure settings shall be defined by the design
documentation.
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5.2.5 Enabling of a change of relay v
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