Pneumatics for FALNS wagons - side-door opening control system
We supply a complete modular pneumatic system for FALNS and FALS self-discharging wagons: control panels, actuator cylinders, G1/2 plate-mounted valves and compressed-air preparation filters. CPP PREMA installations have been operating in wagons since 1995.
What is the pneumatic system of a FALNS wagon used for?
FALNS and FALS self-discharging wagons unload bulk materials through opening side doors and discharge flaps. The pneumatic system is responsible for opening, closing and locking the flaps in the open position, as well as for operational safety during unloading. It must operate repeatably and withstand dust, moisture, vibration and variable temperatures typical of railway operation.
CPP PREMA supplies this system as a modular solution - based on enclosed components that can be installed on a FALNS wagon and easily serviced. The developed system combines proven actuator components with modern modular flap control.
Structure of the modular side-door opening control system
The system retains proven actuator components, while flap control is designed in a modular form. Unlocking and locking the flaps in the open position improves operational safety.
| System component | Location / description | Function |
|---|---|---|
| Right and left control panel | Installed between the wagon side doors | Operation of flap opening and closing from both sides |
| Pneumatic control module | Mounted under the wagon | Control elements and system logic functions |
| Pneumatic hose bundles | In a protective cover against damage | Connection between the control panels, module and actuator components |
| Pneumatic supply to the control box | Connection to the wagon installation | Supply of compressed air to the system |
| Air preparation filter | In the module, with automatic condensate drain | Cleaning of the working medium and protection of control elements |
| ISO D250 pneumatic cylinders | Actuator components at the side-door mechanism | Opening and closing of discharge flaps |
Control panel - operating functions
The control panel enables independent opening of the flaps of two wagon chambers from either side. The panel includes:
- pressure switch button,
- power supply activation / flap closing button,
- flap A opening button,
- flap B opening button,
- common A+B flap opening button,
- system pressure indicator.
The pressure indicator informs the operator whether the installation contains a pressurised working medium - improving safety both during unloading and while the wagon is in transit.
D250x520 pneumatic cylinder - actuator component
The flagship actuator component for FALNS systems: a double-acting cylinder with pneumatic cushioning and clevis, compliant with ISO 6431 and VDMA 24562 (no. 18.2305.ZG). Pneumatic cushioning decelerates the piston before it reaches the end covers, ensuring smooth operation at the end of the stroke.
| Parameter | Value |
|---|---|
| Bore / stroke | D250 / 500 mm |
| Maximum working pressure | 10 bar |
| Nominal pressure | 0.63 MPa |
| Piston rod force at 0.63 MPa | approx. 2945 daN |
| Connection thread / piston rod thread | G1 / M42x2 |
| Operating temperature range | from -30 to +80 °C |
| Service life | 6 million cycles |
| Medium | filtered compressed air, lubricated or non-lubricated |
| Seals | polyurethane PU, VITON |
| Weight | approx. 63 kg |
Construction materials: covers, piston and barrel made of aluminium alloy, piston rod made of carbon steel with a chrome-plated surface, cast-iron clevis, zinc-plated screws. We also select cylinders in other diameters and strokes - according to the specific installation requirements.
FALNS system components from CPP PREMA
Control panels and control boxes
Side-door opening control modules with A / B / A+B flap buttons, pressure switch and pressure indicator.
Pneumatic cylinders
ISO D250 actuator components, including D250x520 cylinders with cushioning and clevis, as well as special versions designed for specific wagon installations.
G1/2 plate-mounted valves
A series of G1/2 plate-mounted directional control valves in railway execution - for controlling the direction and sequence of cylinder operation.
Air preparation filters
Filters and filter-regulators, including versions with automatic condensate drain - for system protection in demanding operating conditions.
Operational and service safety
The system locks the flaps in the open position, while the pressure indicator signals the presence of pressurised medium. Wagon movement with the pneumatic installation under pressure is not permitted - the system supports a safe condition before departure. Hoses are routed in a protective cover to prevent mechanical damage, and the components are selected for operation in demanding service conditions.
Projects
| Project | Scope | Component / type |
|---|---|---|
| Serial installations | Complete side-door opening control system - installations in wagons since 1995 | Control panels, control module, ISO D250 cylinders |
| Railway supplier / integrator | Dedicated plate-mounted railway valves with documentation and cylinder for self-discharging wagons | 24.0401.4312 SPM plate-mounted valve (G1/2); D390 cylinder for 411V wagons |
| Rolling stock maintenance facility | Plate-mounted valves and filters for the pneumatic system - returning customer | 24.0401.4312 SPM valve, 58.0001.12 filter |
Why choose CPP PREMA for FALNS systems?
Experience since 1995
CPP PREMA pneumatic control installations have been operating in self-discharging wagons since 1995 and have received positive feedback from contractors.
Certificates and railway qualifications
ISO 9001:2015 (TÜV), certificate from the Rail Vehicles Institute "TABOR" and CNTK qualification certificate accepted by the German Federal Railway Authority (Eisenbahn-Bundesamt).
Modular and serviceable system
Enclosed modules simplify installation, diagnostics and service, while repair kits extend the service life of the system.
Special designs
Cylinders, valves and control panels adapted to the specific wagon installation - also as replacements for components withdrawn from production.
FAQ - pneumatics for FALNS wagons
What is included in the pneumatic system of a FALNS wagon?
Right and left control panels, pneumatic control module under the wagon, hose bundles in a protective cover, control box supply, air preparation filter and ISO D250 actuator cylinders.
What cylinder is used in FALNS wagons?
Most commonly, a double-acting cylinder with pneumatic cushioning and clevis, ISO D250, is used - for example D250x520, compliant with ISO 6431 and VDMA 24562. We also select other diameters and strokes according to the installation.
Does the control panel allow independent flap opening?
Yes. The system enables independent opening of the flaps of two chambers from either side, as well as common opening of A+B flaps. The pressure indicator shows the presence of pressurised medium.
Is the system safe while the wagon is in transit?
The system locks the flaps and signals pressure. Wagon movement with the pneumatic installation under pressure is not permitted - the system supports a safe condition before departure.
Do you manufacture G1/2 plate-mounted valves for railway applications?
Yes. Our offer includes a series of G1/2 plate-mounted directional control valves in railway execution, used, among others, in FALNS systems.
Do you hold railway qualifications?
Yes. CPP PREMA holds ISO 9001:2015 (TÜV), a certificate from the Rail Vehicles Institute "TABOR" and a CNTK qualification certificate accepted by the German Federal Railway Authority (Eisenbahn-Bundesamt).
Ask about a pneumatic system for a FALNS wagon
Do you need a control panel, cylinder, G1/2 plate-mounted valve, filter or complete side-door control system? Describe the wagon and send the available data. CPP PREMA will select the components or prepare a special version for your installation.