RAILWAY CABLES TRACTION POWER OVERVIEW

Nexans AmerCable’s Traction Power Cable Qualifications HISTORY

Nexans AmerCable’s expertise lies in the design and manufacture of flexible electrical cables intended for the most demanding applications and harshest environments.

Since the early 1970s, AmerCable has been the leading manufacturer of cables for the mining and offshore oil & gas industries. Cables for the mining industry must withstand extreme mechanical abuse, while cables for the offshore oil & gas industry must withstand constant exposure to drilling fluids and sunlight.

The cable insulation and jacketing material used by Nexans AmerCable on its oil & gas cables were originally

developed by General Electric in the 1980s for use on diesel-electric locomotives. The material, trademarked as Gexol®, exhibited outstanding diesel fuel resistance and withstood high operating temperatures. Similarly, the low- smoke crosslinked polyolefin (XLPO) material used on its oil & gas cables was originally developed for use on US Navy shipboard cables which were constantly exposed to damp, brackish environments.

Since 1980, AmerCable has been a leading manufacturer of flexible single conductor diesel locomotive (DLO) cables as well as flexible single conductor Type W portable power cables.

The Nexans AmerCable factory, located in El Dorado, Arkansas, has several dual extrusion lines capable of applying and cross- linking insulation and jacket layers in a single inline process.

This product history and manufacturing capability made AmerCable very well suited to enter the single conductor rail traction power cable market.

Cover page from the early 1990s AmerCable literature for traction power cables.

In the early 1990s, AmerCable began delivering traction power cable to Long Island Railroad (LIRR), Massachusetts Bay Transit Authority (MBTA), Chicago Transit Authority (CTA), New York City Transit Authority (NYCTA), Bay Area Rapid Transit (BART), and Southeastern Pennsylvania Transit Authority (SEPTA). Supply of these traction power cables continued until the early 2000s when a surge in the mining and oil & gas markets consumed AmerCable’s plant capacity.

Since that period, the factory has greatly increased its capacity and has re-entered the traction power cable market. Nexans AmerCable has updated all its industry associated certifications (ex. AREMA, UL RHH-RHW, CSA RW90, etc.) and is fully “Buy America” compliant.

Additionally, in 2012, AmerCable was acquired by Nexans, the world’s second largest cable manufacturer. Being part of Nexans, AmerCable is now able to offer accessories (connectors, fittings, terminations, etc.), complimentary products, and services such as Cable Management.

e-mail: railway.sales@nexans.com

Excerpt from the 1980s original General Electric literature for Gexol® locomotive cables.

An oil major had a large offshore production platform, destined for the Gulf of Mexico, being constructed in a South Texas shipyard. Construction of the facility was near completion

but way behind schedule. For each additional day the facility remained in the shipyard, the oil major was being charged $1 million. A substantial amount of cable that had not been anticipated was needed to complete the project. AmerCable was able to manufacture

and deliver the entire cable package in three weeks. To date, Nexans AmerCable is the preferred cable supplier for this oil major.

A major mining company needed a substantial quantity of a customized Tiger® Brand mining cable delivered to the largest gold mine and the second largest copper mine in the world. This remote mine is located in the province of Papua in Indonesia on top of Puncak Jaya, the highest mountain in Papua. A grand, traditional opening ceremony had been scheduled with all of Indonesia’s top officials attending. One problem. The trailing cable to power the gigantic electric shovels had not been ordered. AmerCable was able to manufacture and ship the cables in five days. The shovels performed and the event was a success.

CABLE MANAGEMENT I RFID REEL TAGS & INVENTORY TRACKING Cable management is a big part of Nexans AmerCable’s services and solutions offering. Rail projects typically require many reels of large, heavy electrical cables. Maintaining the integrity of the cables, cutting to needed lengths, and managing inventory balances can be very costly and time consuming. Nexans AmerCable is currently managing a rail rolling stock provider’s car wiring inventory program for needs throughout the United States. Nexans has established a warehousing facility in New York where it provides Just in Time (JIT) delivery of material to various

projects and distribution to sub-contractors. The management system utilizes Smart Inventory Management (SIM) incorporating RFID tags installed on cable reels at the point of origin so the customer can track their cable reels throughout the supply chain. The cable management program can also integrate with a customer’s ERP platform and generate independent re-orders.

OPERATIONAL EXCELLENCE

Nexans AmerCable, an ISO 9001 certified manufacturer, is known for operational excellence. This is demonstrated by AmerCable’s short lead times and industry best on-time delivery rates (typically 6-8 weeks and 99% on-time).

Nexans AmerCable is also famous for its ability to react quickly in emergency situations, which is summarized by these two examples:

e-mail: railway.sales@nexans.com

Made in America

GEXOL® T-EPR LOW SMOKE TRACTION POWER CABLE 2000V • SINGLE CONDUCTOR • 90°C RATING

NEXA

NS A

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CABL

E 15

00 K

CMIL

GEX

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T-EP

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APPLICATION Gexol® T-EPR DC traction cables with low smoke, zero halogen jackets are designed for tunnel and other below grade installations where these features are required. They are also designed for superior aging and high reliability characteristics. Standard jacket color is black.

INSULATION Gexol® T-EPR insulation is a heat, moisture and chemical resistant, mechani-cally rugged zero halogen compound. The insulation thickness is in accordance with ICEA S-95-658, Table 3-4 column A.

JACKET The thermoset jacket supplied with this cable is a cross linked Polyolefin (XLPO) zero halogen – low smoke thermosetting material. It will provide excellent resistance to mechanical abuse, flame, weathering, most oils, acids and alkalies.

FEATURES • Low smoke – zero halogen construction

• Insulating – non-halogenated proprietary Gexol® T-EPR.

• Extreme heat resistance.

• 90°C Continuous Rating. 130°C Emergency Overload Rating. 300°C Short Circuit Rating

• Mechanically Rugged.

• Exceptional resistance to deterioration and cut through at high temperatures.

• Meets the flame and smoke release requirements of UL 1685 utilizing the FT4/IEEE 1202 procedure.

• Sunlight resistant.

• Resistant to oils, weather and most chemical and alkalies.

• Stable electrical properties at high temperatures.

• Voltage rating: 2000 Volts. 2400V cables are also available.

SPECIFICATIONS A – Conductor: Uncoated copper stranded per ASTM B3. Class B or C per ASTM B8. Optional tin coated copper stranded conductors per ASTM B-33 are also available.

B – Insulation: Meets or exceeds all requirements of AREMA Signal Manual, Part 10.3.19 and ICEA S-95-658.

C – Jacket: Cross linked Polyolefin (XLPO) meets the requirements of AREMA Signal Manal Part 10.3.13 and ICEA S-95-658.

All drawings, designs, specifications, plans and particulars of weights, size and dimensions contained in the technical or commercial documentation of Nexans is indicative only and shall not be binding on Nexans or be treated as constituting a representation on the part of Nexans.

A

B

C

ATC/CBTC AND AXLE COUNTER SYSTEMS LOW SMOKE ZERO HALOGEN • NFPA 130 • QUADS AJ-2Y(L)HBH H45

Train Control Cables from Nexans are well suited for the transit and railway industry where high-speed digital signals relay critical information on train position, speed and other requirements.

APPLICATION Train Control Cables are designed to work with high-speed rail networks. This product family is suitable for in-tunnel applications where reliability and vital circuit safety are mission critical, and fast digital signals are needed to maintain the train separation block.

CONSTRUCTION 1 –Conductor: Solid annealed copper wires to IEC 60228 (Class 1).

Diameter: 0.9mm & 1.4mm

2 –Insulation: Solid Polyethylene Laying-up: Twisted quads. Quads are helically stranded.

Cables from 7 quads and up have two extra conductors of 0.5 mm with perforated insulation. (Surveillance conductors).

3 –Wrapping: One or more dielectric non-hygroscopic tape(s) (Binder Tape) helically laid with an overlap.

4 –Inner Shield: One side copolymer coated aluminum foil bonded to the sheath. 0.40 mm tinned copper wire shall longitudinally contact metal side of tape as drain wire.

5 –Outer Shield: Copper round wire screen.

6 –Bedding Layer: Non-hygroscopic tape(s).

7 –Armor: One layer of helically applied galvanized steel tape. Thickness: 0.255 mm

8 –Outer Jacket: Low Smoke Zero Halogen (LSZH) Outer Sheath. Color: Black UV Resistant

All drawings, designs, specifications, plans and particulars of weights, size and dimensions contained in the technical or commercial documentation of Nexans is indicative only and shall not be binding on Nexans or be treated as constituting a representation on the part of Nexans.

BRINGS ENERGY TO LIFE

TRAIN CONTROL

STANDARDS • NFPA 130 Compliant -

UL 1685 (FT4/IEEE 1202)

• Fire Retardant IEC 60332-3-24 (3C)

• Low Smoke IEC 61034

• Halogen Free IEC 60754-1 HCl≤0.5%

• Ambient Operating Temp. -40°C to +60°C

1

2

3

4

5

6

78

9

MULTIPLE CONDUCTOR AREMA UNDERGROUND FLAME RETARDANT • ARMORED • EPR/CPE • 600V 90°C • DIRECT BURIALAREMA-specified Underground Signal Cables from Nexans are well-suited for the transit and railway industry where wayside control circuits are necessary.

APPLICATION Nexans Underground Signal Cables are designed for the most demanding railway environments where ease of installation combined with outstanding durability are key considerations. These signal cables are suitable for direct burial, in conduit or tray installations where reliability and vital circuit safety are mission critical.

CONSTRUCTION Conductor: Solid or stranded, bare or tinned in accordance with AREMA Signal Manual Part 10.3.16 or 10.3.17.

Insulation: Ethylene-Propylene Rubber (EPR) insulation meeting AREMA Section 10.3.19. Thickness in accordance to ICEA S-95-658.

Armor: 7-mil flat copper alloy tape, Copper 194, over the bedding layer helically wrapped so that a minimum of 20 % overlap is obtained. Meeting AREMA Section 10.3.17

Jacket: A black vulcanized black chlorinated polyethylene (CPE) Compound meeting the performance requirements included in AREMA Section 10.3.20.

All drawings, designs, specifications, plans and particulars of weights, size and dimensions contained in the technical or commercial documentation of Nexans is indicative only and shall not be binding on Nexans or be treated as constituting a representation on the part of Nexans.

BRINGS ENERGY TO LIFE

SIGNAL CABLE

TRA12224 14 3 80 95 0.71 247 TRA12225 14 5 80 95 0.85 323 TRA12226 14 7 80 95 0.91 423 TRA12227 14 12 80 110 1.21 693 TRA12228 14 19 80 140 1.47 1055 TRA12229 14 37 80 140 1.945 1817 TRA12230 14 37 80 155 1.97 1861 TRA12231 9 3 80 95 0.84 403 TRA12232 9 5 80 110 1.035 569 TRA12233 9 7 80 110 1.12 765 TRA12234 9 12 80 140 1.525 1311 TRA12235 6 3 95 110 1.05 662 TRA12236 6 5 95 110 1.255 889 TRA12237 6 7 95 140 1.425 1297

Approx. Weight lbs. per 1,000 ft.

Part Number

Size AWG

Number of Conductors

Insulation Thickness

(mils)

Jacket Thickness

(mils)

Outside Diameter

(in)

STANDARDS • AREMA Communications

and Signaling Manual Sections 10.3.19 and 10.3.20

• High strand count conductors can make this product more flexible and easier to install.

• 40°C through 90°C temperature range

• Sunlight Resistant

• Resistant to oils and most chemicals

APPLICATION Contact wire for railway catenary line.

DESCRIPTION Made of high purity copper CuETP or CuMg0.2 alloy, contact wire is shaped wire that comes into contact with the pantograph of the train. It provides power from the catenary line to the train. Contact wire is a key part of the catenary line (with dropper and messenger wires).

Thanks to continuous copper casting and contact wire drawing, we are able optimize contact wire properties for full control along the transformation process, from raw materials to the finished product.

Nexans provides standard contact wire solutions (ASTM or European products) as well as contact wires that meet specific needs. Feel free to contact us with your requirements. We are continuously developing contact wires with optimized properties.

THIRD-PARTY CERTIFICATION Mechanical properties ( UTS, YS, E and A%) and Thermal expansion (CTE) certified by IMR Test Labs CurtissWright.

All drawings, designs, specifications, plans and particulars of weights, size and dimensions contained in the technical or commercial documentation of Nexans is indicative only and shall not be binding on Nexans or be treated as constituting a representation on the part of Nexans.

STANDARDS INTERNAIINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONALTIONALINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONALINTERNATIONAL

• EN 50149: 2012

NANNATIONALTIONALNATIONALNATIONALNATIONALNATIONALNATIONALNATIONAL

• ASTM B 47; ASTM B 9

• ASTM B47 – 95a

• ASTM B9 90

• EN 50 149: 2012

BRINGS ENERGY TO LIFE

CONTACT WIRE

B47 Nexans B47 Nexans B47 Nexans B47 Nexans 3/0 3/0 4/0 4/0 300MCM 300MCM 350MCM 350MCM

Nominal Size Cmils 167800 167800 211600 211600 300000 300000 350000 350000

Area Cmils 167300 167300 212000 212000 299800 299800 351200 351200

Tensile psi >48500 51200 >46600 52214 >44200 49300 >42800 46400 Strength

Elongation % >3.25% 610% >3.75% 610% >4.50% 610% >4.50% 610% After Fracture

Electrical % IACS >97.2% 99% >97.2% 99% >97.2% 99% >97.2% 99% Conductivity

Resistivity x10_Ω.m <1.7745 1.74 <1.7745 1.74 <1.7745 1.74 <1.7745 1.74

Linear Mass lb/mile 2567-2781 2682 3253-3525 3388 4600-4984 4729 5388-5836 5613

Maximum Ω/Km <0.209 0.205 <0.165 0.162 <0.1168 0.115 <0.0997 0.0978 Resistance Per Km ²

Technical Datasheet

UnitsB47 - 95a

Typical Values Nominal Sections1

1) ASTM B47, B116 – Regular grooved wire, Fig-8 and Fig-9 profiles available 2) Calculated from resistivity and area at 20°C

CONTACT WIRE MADE OF HIGH PURITY COPPER (CUETP)

CONTACT Railwaynetworks.NA@Nexans.com

Nexans AmerCable 350 Bailey Road - El Dorado, Arkansas USA (870) 862-4919 • (800) 643-1516 • Fax (870) 862-9613 e-mail: railway.sales@nexans.com www.nexansamercable.com © 2020, AmerCable Incorporated 2_20

Nexans has the world’s largest rail and transit wire and cable portfolio.

CERTIFICATIONS:

• AREMA

• UL RHH-RHW

• CSA RW90

• “Buy America” compliant