Power & Control Cable for railway applications
450/750V Trackfeeder Cable
At a Substation, the AC current is transformed and rectified into DC 450/750V. Trackfeeder cables are used to take provide the 450/750 volt DC supply from Traction Substations and Track Paralleling Huts to the track including the conductor rails, negative cable connections and where appropriate bonding. The single core trackfeeder cable has a Class 2 stranded aluminium or tinned copper conductor, a PETP (Polyethylene Terephthalate) separator and a black CSP sheath. Positive trackfeeder cables commonly used include 1x1000mm² (aluminium), 1x630mm² (copper) and 1x500 mm²(aluminium). Negative trackfeeder cables commonly used include 1x800mm² (aluminium), 1x500mm² (copper), 1x240mm² (aluminium), 1x161mm² (copper) & 1x150mm² (aluminium). The applicable standard is NR/PS/ELP/21101. BS 6360 and BS 6899 for UK NETWORK RAIL and NF-F5525 for France RATP.
450/750V LSZH Earthing Cable
Earthing cables, commonly named as LSZH 6491B conduit wiring cable, are used in switch and relay rooms, stations and general areas as required providing an effective protective earth. These cables are commonly installed in ducts and used in the power network within a station – from the ticket kiosks, passenger information displays, entrances and exits to the lifts and escalators. The applicable standards is BS 7211 and EMESP-14-026 for UK NETWORK RAIL.
0.6/1KV Steel Wire Armoured LSZH Cable
Steel wire armoured 0.6/1KV LSZH power and auxiliary control cables are designed for supply of power to ticket kiosks, passenger information displays, entrances and exits, lightning systems, lifts and escalators in the concourse. They can be installed directly underground, outdoors, indoors and in cable ducting. These cables have Class 2 stranded copper conductors, XLPE insulation and aluminium or steel wire armour. The applicable standard is BS 6724 and EMESP-14-027 for UK NETWORK RAIL. LSZH cables are employed for installation in the concourse where fire, smoke emission and toxic fumes may create a potential threat during the fire.
Fire Integrity Cable
Fire Integrity Cable, are designed for installation typically in public help points (PHP), public address (PA), station announcement platforms (SAP), fi re alarm and CCTV systems, platform screens and door, entrance and exits, lifts and escalators in a station where vital circuit integrity must be maintained in the event of a fi re. The fi re integrity cables also furnish a complete fire detection system for difficult environments (like tunnels) providing early warning and no false alarms. The fire integrity cables consist of solid or stranded copper conductors, silicon rubber insulation, an optional aluminium tape and a LSZH sheath. The applicable standards include BS 7629-1, BS 5839-1: 2002, BS 8434-1: 2003, BS EN 50200 PH30, BS 6387 C W Z, IEC 60332-3, IEC 60332-1, BS EN 50265, BS EN 50266, BS 50267, BS EB 50268, IEC 60754 and IEC 61034). These cables comply with LU Section 12 station regulations.
Aluminum Power Cable
Aluminium power Cables are designed for the distribution of trackside signalling power. These 2 and 4 core power cables have a sector shaped solid aluminium conductor, XLPE or PVC insulation, a PETP separator and a black PVC sheath. The applicable standards are BR880, BS 5467 and BS 6346.
Point Heating Cable
Swtichpoints along a railway line allow the train to change between tracks. Many railway switchpoints suffer during the winter months, from snow and ice blocking the moving rails and point mechanisms, causing failures and disruption to traffi c. It is vital that these Points continue to operate effectively in adverse weather conditions. To do so, Switchpoint Heating system are installed in the web of the stock and moving rails and applies heat through point heating cable effectively to the areas most prone to the effects of snow and ice. The point heating cables consist of Class 5 fl exible tinned copper conductors, EPR (Ethylene Polypropylene Rubber) insulation and a PCP (Polychloroprene) sheath. These heavy duty cables offer protection from abrasion and mechanical impact whilst maintaining fl exibility to ease installation and provide power and control in Points Heating systems. The applicable standard is NR/SP/ELP/40045 (formerly RT/E/ PS40045) and BS 7919
Bare Conductor and Screening Conductor Cables
In overhead line networks, screening conductor cables are used to screen telecommunication cables from electrical interference caused by the potential of a high voltage cable. These cables can absorb the magnetic fi eld generated by the overhead high voltage cables and minimize the effects of this interference. Bare and covered screening conductor cables are usually installed in parallel to the communication cable to provide effective zonal screening. The conductor section is usually 150mm² and 240/250 mm². Screening Conductor Cable has a single core stranded aluminium conductor and a black PVC or LSZH sheath, and a Bare Conductor consists of a single core stranded aluminium conductor. Screening conductor cables are denoted as FTN screening conductor cables by NETWORK RAIL. The applicable standard is NR/ PS/TEL/31102 (BR1817)/BS 6485.
NSGAFOU Rail Cable
NSGAFOU cables are designed for use in wiring of devices in the electrical traction units that power the wheels and auxiliary controls (such as breaks and heating systems). NSGAFOU Rail Cable is a single core cable with a Class 5 fl exible tinned copper conductor, EPR insulation, and a Black PCP sheath. These cables are used for existing train maintenance only.
6.35/11KV, 12.7/22KV & 19/33KV & 25/44KV Medium Voltage Cable
These medium voltage cables are designed for the distribution of three phase A.C. electrical power supplies at nominal system voltages of 11KV, 22KV 33KV and 44KV to traction substations on D.C. electrified lines. The 25KV two core concentric cables are mainly used to deliver 25KV single phase electrical power supplies, typically, to feeder stations on A.C. electrifi ed lines. The 25KV single core cables are mainly used to carry 25KV electrical power supplies from track-side switching stations to the overhead line equipment on A.C electrifi ed lines. Armoured 11kV cables are used to distribute power between substations. Over longer distances, 33KV cables are generally specified.
This 11-33kV cables have class 2 stranded plain aluminium or copper conductors, extruded semi-conducting XLPE conductor screen, XLPE insulation and cold strippable semi-conducting XLPE insulation screen, water blocking tape, metallic screen of copper wires and copper tapes, aluminium or steel wire armour and a PE, PVC or LSZH sheath. The applicable standard includes NETWORK RAIL Line Standard NR/PS/ELP/00008, BS 6622 or BS 7835 (LSZH version). These power cables are available in various sizes: popular sizes of 1x240mm² solid aluminium, 1x185mm² solid aluminium and 1x300mm² stranded copper are commonly used.
DC Traction Cables for 1500 DC Electrified Lines
Most of the railways use a 1500VDC, single overhead conductor catenary system with traction return via the running rails. The traction power system provides 1500V DC power to the train through two power rails, a positive and negative, mounted to the side of the guide beam. The system provided for traction supply from substations connected to lines via fault sensing circuit breakers. Return current is collected by connecting the substation negative busbar to the rail, usually by way of impedance bond. DC traction cables are used to connect impedance bonds and negative busbar to rails and between neutral points of the impedance bonds mounted in track. DC traction cables are designed for traction return for non electrical areas or electrifi ed areas using 1500DC traction.
DC traction cables are used as positive and negative cables for railway system. Positive feeder cables connect the dc feeder circuit breakers in the traction substation to the contact rail system. Negative feeder cables are used to connect the rectifi er negative bus in the traction substations to the shunts at the running rail.
In normal traction area, the standard size is 120mm² copper. This may be provided by 608/0.5mm copper or 925/0.5mm (185 mm²) aluminium. In heavy traction area, standard size is 185mm² copper. This may be provided by 962/0.5mm copper or 1525/0.5mm (300mm²) aluminium.
DC traction cables are characterized by superior aging and stable electrical characteristics at high temperature, extreme heat resistance and sunlight resistance, suitable for installation in damp locations inside the tunnels. They can be used for direct burial or in ducts, subject to vibrations of train operation.
Conductor shall be anneal uncoated copper, concentric and round. An extruded semi conducting thermoset compound shall be applied over the conductor. This conductor shield is fi rmly bonded to the overlying insulation with a similar temperature coeffi cient of expansion as the EPR insulation. The EPR insulation can withstand oil, heat, stress and extreme temperature, being moisture, chemical resistant and mechanically rugged. The cables shall have at least 3.9mm or 155mil insulation thickness. The sheath shall be either crosslinked polyolefin low smoke zero halogen compound or CSP. The LSZH or CSP sheath applied with this cable provides excellent resistance to mechanical abuse, flame, weathering, most oils, acids and alkalines.