Rolling Stock Cable

Customised
Rolling Stock Cables

Halogen-free cables built by Elegar Kerpen for traction, auxiliary, control and data circuits on locomotives, metro cars, coaches and EMUs, engineered to EN 50264, EN 50306 and EN 50382 with EN 45545-2 fire performance.

Let's Connect View Specifications
Multicore rolling stock cable cross-section with six tinned copper cores, a green/yellow earth core, halogen-free insulation and an LSZH outer sheath
Multicore Rolling Stock Cable

Disclaimer: Cross-section shown is a representative illustration; actual product construction and dimensions may vary.

3.6/6kV
Max Voltage Grade (Global Specs)
61 Cores
Max Core Count
0.5–400mm²
Cross-Section Range
8 Standards
EN · IEC
About this product

Rolling Stock Cables

At Elegar Kerpen, one of the most trusted wires and cables manufacturers in India, our rolling stock cables are engineered for the onboard electrical systems of locomotives, metro and light rail vehicles, EMUs, coaches and wagons. Every construction is halogen-free, cross-linked and built to survive three decades of vibration, temperature cycling, oil, ozone and abrasion in the confined, safety-critical environment of a moving train.

Rolling stock cables are a specialised family of railway cables that carry traction power, auxiliary supplies, control commands and data across a vehicle, from the pantograph and roof line down through the underframe and bogies to driver desks, HVAC units and passenger systems. Because escape from a train is slow, their defining requirement is behaviour in a fire hazard: fire resistance, smoke density and toxicity are all controlled to prevent fire from spreading.

Modern electric multiple unit at a station platform, a typical application for rolling stock cables
Use cases

Applications of Rolling Stock Cables

From the pantograph to the passenger saloon, every onboard circuit on a modern rail vehicle.

01
Traction Power Circuits
Carrying high-current traction supply from the transformer and converter to traction motors, rated up to 3.6/6 kV with cross-sections to 400 sq.mm for heavy haul and high-speed applications.
02
Pantograph & Roof-Line Wiring
Roof-mounted runs exposed to UV, ozone, rain and ballast dust. Cross-linked halogen-free sheaths resist weathering and surface tracking at high altitude and in coastal service.
03
Bogie & Underframe Connections
Below-floor routes subject to continuous vibration, stone impact, brake dust and de-icing chemicals. Abrasion- and oil-resistant sheathing keeps cores protected over decades of duty.
04
Inter-Vehicle Coupler Jumper Cables
Highly flexible Class 5 and Class 6 constructions that flex through the coupler and gangway as coaches articulate, carrying train line power, control and data between vehicles.
05
Driver Desks & Control Panels
Thin-wall EN 50306 cables for dense harnesses inside cabinets and cab consoles, where compactness and weight saving matter as much as electrical performance.
06
Auxiliary & Converter Circuits
Auxiliary power supplies, battery chargers and converter connections operating at elevated temperature close to power electronics and forced-air cooling paths.
07
HVAC, Lighting, Fire Alarm & PA Systems
Air conditioning, saloon and emergency lighting, fire detection and alarm loops, public address and passenger information circuits routed through interior voids and ceiling panels.
08
Signalling, Databus & Communication
Screened pairs and quads for MVB, WTB, CANbus, RS-485 and onboard Ethernet, maintaining signal integrity in the electromagnetic noise of traction converters.
Technical data

Rolling Stock Cable Construction

Standard wall, medium wall, thin wall and high-temperature constructions. Full parameters are available in our product catalogue, with custom builds on request from our applications engineering team.

Rolling Stock Cable Construction Parameters
Voltage Grades300/500 V, 0.6/1 kV, 1.8/3 kV and 3.6/6 kV, plus 300 V thin wall to EN 50306
Core CountSingle core, and 2 to 61 cores depending on conductor size
ConductorFinely stranded annealed tinned copper, Class 5 / Class 6 to IEC 60228
Cross-Section Range0.5 sq.mm to 400 sq.mm
InsulationCross-linked halogen-free polyolefin (XLPO), EPR / EPDM, EVA, or silicone rubber for EN 50382 high-temperature grades
ScreeningTinned copper wire braid, or Al-mylar tape with tinned copper drain wire, for EMC-sensitive control and databus circuits
Inner Sheath / BeddingHalogen-free, low smoke cross-linked elastomer
Outer SheathLSZH cross-linked polyolefin or elastomer, oil, fuel, ozone and abrasion resistant
Max Conductor TemperatureEN 50264, EN 50306, EN 50382: 90°C / 105°C / 120°C / 150°C
Short-Circuit Temperature200°C (EN 50264), 160°C (EN 50306), 350°C (EN 50382)
Min Operating Temperature−40°C (EN 50264 / EN 50306), −25°C (EN 50382)
Fire PerformanceEN 45545-2 HL1 to HL3, requirement sets R15 & R16; tested to EN 50305, EN 60332-1-2, EN 60332-3-24 and EN 61034-2
Standards ComplianceEN 50264, EN 50306, EN 50382, EN 50355, EN 50343, EN 50200, EN 45545-2, IEC 60228
Compliance

Rolling Stock Cable Standards

EN 50264
Power & Control, to 3.6/6 kV
EN 50306
Thin Wall, to 300 V
EN 50382
High Temperature, 120/150°C
EN 45545-2
Fire Behaviour, HL1–HL3
EN 50355
Selection & Guide to Use
Product enhancements

Additional Properties

Rolling stock cables can be manufactured with:

EN 45545-2 HL3 fire performance with flame propagation, smoke density and toxicity controlled
Oil, fuel, grease and hydraulic fluid resistance for underframe and bogie routes
Ozone, UV and weathering resistance for roof-mounted and external installations
Cold bend and cold impact performance down to −40°C for winter service
Enhanced abrasion and tear resistance against ballast strike and cable-route chafing
Electron-beam cross-linked thin-wall insulation for weight and space savings
Braid or tape screening for EMC protection near traction converters and inverters
RoHS, REACH & ROCHA compliance, with IRIS-aligned quality and traceability
Product advantages

Why Elegar Kerpen Rolling Stock Cables?

Eight measurable advantages built into every cable, from manufacturing floor to depot installation.

Certified Fire Safety
Meets EN 45545-2 hazard levels HL1 to HL3 under requirement sets R15 and R16, so no further fire testing is needed at vehicle level.
Zero Halogen, Low Smoke
Halogen-free compounds release no corrosive or toxic gases in a fire, protecting passengers, crew and onboard electronics during evacuation.
Weight & Space Savings
Thin-wall and medium-wall constructions cut harness diameter and mass, lowering energy consumption and easing routing through crowded conduits.
30+ Year Service Life
Cross-linked insulation and sheathing resist thermal ageing, ozone and hydrolysis across the full overhaul life of the vehicle.
Vibration & Flex Endurance
Class 5 and Class 6 flexible conductors withstand constant vibration and the repeated flexing of inter-vehicle jumpers and bogie loops.
Oil & Chemical Resistance
Tested against mineral oil, fuel, brake fluid and de-icing agents so underframe cables hold their properties in service.
Weather Resistance
Sheathing stands up to UV, ozone, rain and temperature extremes on exposed roof and external runs, rated from −40°C to +90°C as standard and up to +150°C in EN 50382 constructions.
EMC-Ready Screening
Braid and foil screen options preserve control and databus signal integrity alongside high-power traction circuits.
Support FAQ

Frequently Asked Questions

Common technical and commercial questions about Elegar Kerpen rolling stock cables.

What makes a rolling stock cable different from an industrial cable?
Fire behaviour and durability. Because evacuating a moving train is slow, rolling stock cables must limit flame propagation, smoke density and gas toxicity under EN 45545-2. They also use halogen-free cross-linked compounds and flexible tinned copper conductors to survive vibration, oil, ozone and temperature cycling for the life of the vehicle.
What is EN 45545-2 and which hazard level do your cables meet?
EN 45545-2 sets the fire behaviour requirements for materials on railway vehicles, graded HL1 to HL3. The higher the level, the slower the likely evacuation, such as sleeper trains or underground operation. Our rolling stock cables are built to satisfy HL3 under requirement sets R15 (interior) and R16 (exterior).
What is the difference between EN 50264, EN 50306 and EN 50382?
EN 50264 covers standard and medium wall power and control cables up to 3.6/6 kV at 90°C. EN 50306 covers thin wall cables up to 300 V at 105°C, where compactness and light weight matter most. EN 50382 covers high-temperature cables rated 120°C and 150°C for use near traction equipment and power electronics.
Are your cables suitable for roof-mounted and underframe installations?
Yes. Sheathing compounds are formulated for UV, ozone and weathering on roof runs, and for oil, fuel, ballast impact and abrasion below the floor. Cold bend and cold impact performance is maintained down to −40°C for cold-climate service.
Can you supply screened cables for databus and signalling circuits?
Yes. We offer tinned copper braid screening and aluminium-mylar tape with drain wire, in individual, collective or combined form, for MVB, WTB, CANbus, RS-485 and onboard Ethernet circuits routed alongside traction power.
Do you offer custom core counts, colours and printing?
Yes. Rolling stock cables are supplied single core or in 2 to 61 core configurations from 0.5 sq.mm to 400 sq.mm, with customer-specified sheath colours, core identification and surface printing to suit builder and operator wiring standards.
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