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Raiway Applications-Rolling Stock: Rules for installation of Wire Harness

Raiway applications rolling stock rules for installation of wire harness

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Page 1: Raiway applications rolling stock rules for installation of wire harness

Raiway Applications-Rolling Stock: Rules for installation of

Wire Harness

Page 2: Raiway applications rolling stock rules for installation of wire harness

Senior Electrical System Design and

Wire Harness Design Engineer

/hamditosun

Design & Development

Professional in vehicle electrical distribution systems

Process Studies and Improvements

Systems Design and Integration

Material Cost Reductions for vehicle electric systems

Research & Analysis

Process Studies and Improvements

[email protected]

Scan the QR code to add me on

WeChat

Page 3: Raiway applications rolling stock rules for installation of wire harness

Contents

1. What is a Wiring Harness?

2. Technical Requirements

3. EMC Requirements

4. Marking

5. Testing

Page 4: Raiway applications rolling stock rules for installation of wire harness

1. What is a Wiring Harness?

A cable harness, also known as a wire harness, cable assembly, wiring assembly or wiring loom, is an assembly of ccables or wires which transmit signals or electrical power. The cables are bound together by straps, cable ties, cable laching, sleeves,electrical tape, conduit, a weave of extruded string, or a combination thereof.

Commonly used in automoblies, as well as construction machinery, cable harnesses provide several advantages over loose wires and cables. For example, many aircraft, automobiles and spacecraft contain many masses of wires which would stretch over several kilometres if fully extended. By binding the many wires and cables into a cable harness, the wires and cables can be better secured against the adverse effects of vibrations, abrasions, and moisture. By constricting the wires into a non-flexing bundle, usage of space is optimized, and the risk of a short is decreased. Since the installer has only one harness to install (as opposed to multiple wires), installation time is decreased and the process can be easily standardized. Binding the wires into a flame-retardant sleeve also lowers the risk of electrical fires.

Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 5: Raiway applications rolling stock rules for installation of wire harness

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 6: Raiway applications rolling stock rules for installation of wire harness

Production

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pin board (assembly board), according to the design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 7: Raiway applications rolling stock rules for installation of wire harness

Production

In spite of increasing automation, in general, cable harnesses continue to be manufactured by hand, due to the many different processes involved, such as:

• routing wires through sleeves,

• taping with fabric tape, in particular on branch outs from wire strands,

• crimping terminals onto wires, particularly for so-called multiple crimps (more than one wire into one terminal),

• inserting one sleeve into another,

• fastening strands with tape, clamps or cable ties.

Manual production remains more cost effective than automation, especially with small batch sizes.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 8: Raiway applications rolling stock rules for installation of wire harness

Production

Pre-production can be automated in part. This affects:

• Cutting individual wires (cutting machine),

• crimping terminals onto one or both sides of the wire,

• partial plugging of wires prefitted with terminals into connector housings (module),

• soldering of wire ends (solder machine)

• twisting wires.

Testing the electrical functionality of a cable harness can be done with the aid of a test board. The circuit diagram data are pre-programmed into the test board, where harnesses can be tested individually or in multiple numbers.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 9: Raiway applications rolling stock rules for installation of wire harness

2. Technical Requirements General Requirements

1. Selection of type and size of cables

2. Bundling of cables

3. Flexibilty of cables

4. Minimum cross-sectional area of conductors

5. Use of green-yellow color

6. Bending radii and other mechanical requirements

7. Re-termination

8. Busbars

9. Connections to busbars

10. Seperation of cables for safety reasons

11. Provisions for refurbishment and maintenance

12. Fire prevention

13. Provisions of spares for control cabling

14. Requirements for fixing

15. Clearances and creepage distances

16. Requirements for terminating conductors

17. Use of heat-shrinkable sleeves

18. Connections for return current

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 10: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

General Requirements

• Cables on rolling stock shall not be used for any purpose other than for transmission, distribution and collection of electrical enery, electrical controls or monitoring systems.

• All components of cabling shall be selected, installed, protected, used and maintained so as to prevent danger.

• The electrical connections shall be made in such a way that they can not be unintentionally disconnected or interrupted during service by thermal effects, dynamic loads as shock, vibration, car body motions, etc. That are to be expected.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 11: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.1. Selection of Type and Size of Cables

2.2.1 General

When selecting cables or busbars the expected operating conditions should be taken in to account. These should include but are not limited to the following parameters:

• Voltage

• Current

• Overload current

• Voltage drop

• Short circuit current

• Shape and frequency of current

• Fusing characteristic of the protection device

• Grouping of cables

• Ambient temperature and temperature due to load current

• Methods of installation

• Predicted cable life time

• Presence of rain or steam or snow or accumulation of condensing water

• Presence of corrosive, polluting or damaging substances

• Mechanial stresses

• Radiation such as sunlight

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 12: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Consideration should be given to the expected lifetime of the cabling compared with the expected lifetime of the vehicle.

Short circuit conditions should additionally .Recommended short circuit ratings for rolling stock cables are given in EN 50355. Short circuit and overload conditions should be checked with respect to the fusing characteristic of the protection device and the resistance of the chosen cable. See example in figure 1.

Figure 1 – Example of short circuit condition where cable size will have influence on protection device behaviour

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 13: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Consideration should be given to the expected lifetime of the cabling compared with the expected lifetime of the vehicle.

The cross-sectional area of any conductor shall be not less than the value.

2.1.2 Selection of Cable Size for Control Cables

Control cables, which are intended to carry control signals only, shall have a minimum conductor cross-sectional area as specified in 5.5. This is also valid if the load current would make a smaller cross-sectional area possible.

2.1.3 Selection of Cable Size for Cables for Power Distribution, on the Basis of Load Current

This subclause specifies a method for caiculation of continuous maximum load current of different cable sizes dependent on their method of installation and ambient temperature, to enable cables to be selected so as to ensure that the predicted lifetime is achieved.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 14: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements A) The load current

When the circuits being supplied by the cable is in continuous or sustained cyclic operation, Iload

shall be calculated according to the following equation:

Where

t1 is the duration of a typical duty cycle during service, in minutes (min)

i is the instantaneous current – including overload, if any – in amperes (A)

When operation is not continucus or sustained cyclic, Iload shall be calculated according to

Annex A.

B) The current carrying capacity

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 15: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements C) Selection of cable size

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 16: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.1.4 Cables intended for power distribution – Slection on the basis of protection davice

In cases where the load current I load is not exactly defined, the rating of the

protection device may be chosen according to the maximum load current that can be expected. The conductor size shall then be selected according to the rating of protection device in accordance with Table 2. This applies to all cable types with

T C(MAX) of at least 90c, at an ambient temperature of maximum 45c.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 17: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.1.5 Motor Cables

Traction motor cables shall be sized according to the procedure specified in. Higer flexibility of cables should be considered when selecting cable type

(Class 6)

2.1.6 Cables for Protetive Bonding

Cables for protective bonding shall be sized and installed.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 18: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.2 Bundling of Cables

If several cables are to be laid together as a bundle, the following factors should at least be taken into consideration:

• Thermal requirements

• EMC requirements

• İnsulation levels

• Mechanical aspects, such as strength of bundle, weight of bundle and available space.

If cables with different cross-sectional area are to be bundled together, the mechanical stresses should be considered.

2.3 Flexibillity of Cables

If high flexibility is required, stranded conductors of class 6 in accordance with HD 383 S2 should be used. In all other cases, stranded conductors of class 5 in accordance shall be used.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 19: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.4 Minimum Cross-Sectional Area of Conductors

Single- core cables laid separately, or cables laid side by side, connecting electrical components in different locations inside rolling stock vehicles (e.g for connections between locations A, B and C as shown in Figure 3) shall have a nominal conductor cross-sectional area of at least 1,0 mm2.

Smaller cross-sectional areas shall be allowed under the following conditions:

• For internal wiring in racks or assemblies or in electronic equipment or precabled devices, if the circuit is protected against overload and if the mechanical strength is given (e.g inside A or B or C as shown in Figure 3)

• For multi-core cables, bundled cables, databus connections etc., if the mechanical strength is provided and if the load current in all operational cases allows this

• For devices specified and tested as a complete unit for use in rolling stock.

Figure 3 – Locations in rolling stock, concerming use of minumum cross-sectional areas for conductors HAMDİ TOSUN

Senior Electrical System Design and Wire Harness Design Engineer

Page 20: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.5 Use of Green and Yellow Colour

When the protective earth conductor in rolling stock is identified by colour, a green/yellow combination shall be used (general abbreviation GNYE).

2.6 Bending Radi and Other Mechanical Requirements

Cables shall be installed so that the minimum bending radii for fixed-installation cables which are flexing during service are not less than those given in the relevant product information or cable standard.

2.7 Re-termination

Single and multi-core cables with a nominal conductor cross-sectional area of 16 mm2 or less installed on rolling stock should have sufficient spare length at each termination to allow for at least 3 re-terminations.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 21: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.8 Busbars

Busbars should be made of copper or aluminium. On contact surfaces, precautions shall be taken to prevent contact resistance values from increasing with time in particular due corrosion effects or creep.

Busbars shall conform to the relevant international, European or national standard. The selection of the type and dimensions of busbars shall be at the discretion of the vehicle manufacturer. The sizing procedure shall include the of ambient temperature.

2.9 Connections to Busbars

Electrical connections between busbars and equipment or between different bar sections or between different devices shall be if relative movement can be expected.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer HAMDİ TOSUN Senior Electrical System

Design and Wire Harness Design Engineer

Page 22: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.10 Separation of Cables With Different Voltage Ratings or Power Levels for Safety Reasons

Measures in order to prevent electrical hazards to persons shall be according to EN 50153.

EN 50153 specifies the use of meansures like bonding, insulation, prevention of access, automatic disconnection of power supply in hazardous cases, vehicle protective bonding, warning labels with respect to different voltage bands and possible occurrence of direct and indirect contact.

When grouping cables, cables carrying different voltage or power levels shall be separated as far as practicable.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 23: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Cable Category Duty of Cable (examples)

High voltage or power Power supply, traction motor and braking resistor cables

Medium voltage or power Auxiliary supply cables, including battery circuit cables for these

Low voltage or power Control and signal cables, including battery circuit cables for these

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Separation shall be by distance, insulating barriers or earthed metallic barriers (see figure 4 and figure 5).

Separation barriers or screens or sleeves shall have the same mechanical strength and resistance to fire and insulation properties as the insulation of the cables in the higher category.

Example of division of cables into three categories for safety reasons

Page 24: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Where separation by distance can not be achived, for example because of restricted space available, the cables shall be separated by a partition or by insulation (see figure 5). Exceptions shall be limited to cases where no practical solutions are possible (close to terminal strips, at crossing, etc.).

The individual return cables should be treated in the same way as their matching forward supply cables in all categories.

For cables not electrically protected on the train, EN 45545 shall be as short as possible.

If the high voltage/power cables have to be laid in a passenger compartment or driver’s cab, they shall be installed in closed earthed metallic tubes or behind earthed metallic enciosures.

The number of cable categories, the nominal voltage/power limits and exceptions from these rules shall be agreed between the manufacturer and the purchaser.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 25: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Figure 4 – Separation of cables by required distance: D >2 d and D > 0,1M

Figure 5 – Examples of separation of cables by barriers or by insulation

Page 26: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.11 Provisions for refurbishment and maintenance, including inspection and repair

The design of a new vehicle should take into account the fact that on average once in its lifetime it is likely to undergo a major refurbishment (redesign or extensive modifications) or be extensively repaired.

The design shall include the following provisions for this:

• Cables , cable conduits, equpment, terminal , etc., shall be accessible.

• Provision shall be made to allow replacement and repair of cables (provisions for pulling new cables through conduits etc., ensurring space is available for sclicing).

Cables laid in tubes should not be fixed together as a bundle, otherwise a large amount of work would be needed to rearrange individual cables. For the same reason, the bending radius and the cross-sectional area of the tubes should be as possible. Discontinuous tubes (tubes with holes , breaks etc.) may be required in order to increase accessibility.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 27: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Cables which are exposed to flexing and bending stress during service (car to car connections, etc.) should have good accessibility. The transition between the flexing and fixed parts of the cabling should be as smooth as possible.

For cables laid in tubes or conduits the ratio between the actual amount of cables including spares and the maximum possible amount of cables laid into a straight tube or conduit should not exceed 60%, to allow for replacement/refurbishment.

If the concerned cables are fixed (i.e. Not being moved, bent or flexed during service), insulated splicing connectors may be used during repair and refurbishment for cross-sectional areas up to 6 mm2.

For new vehicles, splicing shall not be used in the orginal design , or manufacture.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 28: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Disconnection points in the cabling should be selected carefully and should be agreed between the manufacturer and the purchaser. Disconnection points should be selected so that the need for dismounting of cabling because of repairs or planned maintence is minimized. Cables with low life time expectancy (for instance flexible intercar cables) should be easy to renew with minimum need for dismounting.

2.12 Fire prevention, cable laying and cabling behaviour in case of fire

For details about cable and cabling materials (such as fixings, heat shrink sleeving, tubes) concerning fire propagation, resistance to fire and reaction to fire (e.g. Smoke contents),

For certain critical functions (emergency light control, door operation, emergency brake application, fire extinguisher control etc.), it may be necessary to use cables, splices, terminations and connections with special construction that retain integrity for a defined time in case of fire. Regarding this, EN 50200 shall apply.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 29: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.13 Provision of Spares for Control Cabling

For cables connecting electrical components in different locations inside rolling stock vehicles, 10% or at least 2 spare cores shall be provided in every multi-core cable or bundle of cables containing more than 10 cores. An appropriate number of spare contacts in the plugs, terminals, coupler contacts etc.) or space available for additional connectors should be provided.

The number of spare cores shall be that amount provided at the date of completion of assembly of the firs vehicle.

This number of spare cores needed depends on the construction of the cables and connectors and on the method of laying the cables. In cases where the cables are inaccessible (when they are in tubes etc.) the number of spare cores should be increased. Concering spares in connectors, such as plugs to be mounted in the plug housing or whether they are to be delivered as separate parts together with tools for the necessary work, to avoid the need to change complete plugs later.

Unless otherwise agreed between the manufacturer and the purchaser, the ends of spare cores shall be rolled up and fixed in an accessible place.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 30: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.14 Requirements for Fixing

Cables other than those running in tubes or conduits shall be secured by mechanical fixings or fastenings.

Cables ahould be secured at maximum intervals as follows, unless the cable manufacturer has specified other values:

a) Power cables,multi-core cables and cable bundles

• 300 mm when cables are running in the horizontal direction,

• 500 mm when cables are running in the vertical direction.

b) Single –core cables for low power, laid singly

• 150 mm between fixings when cables are running in the horizontal or in the vertical direction, also between a termination point and the first fixing.

The fixings shall be selected to take into account the cross-sectional area of the cable bundles, and expected operational and environmental conditions during the operational lifetime of the vehicle, such as shock and vibrations and cable temperature.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 31: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

Cable ties shall be selected in accordance with the following:

• Cable ties shall be selected with respect to the fact that they do not damege yhe cables or detonate their prorties;

• Cables ties shall be selected which are resistant to the conditions in which the cables are installed (e.g. Exposure to diesel oil and UV radiation);

• The fire performance of cable ties shall conform to EN 45545

2.15 Clearances and Creepage Distances

For the uninsulated parts of electrical installations, clearances and creepage distances shall be in accordance with EN 50124

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 32: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.16 Requirements for Terminating Conductors

All conductors except spares, but including non current carrying conductors provided for protective earhing shall have terminations on both ends. Each termination points shall have a specific preparation of the cable end and shall have a matching part on the terminal or device side . Both the current rating and the temperature rating of both sides of the termination point shall be not less than the maximum load to be expected in service.

The following conditions should be taken into account:

• Fire behaviour

• Thermal resistance of all involed components

• Mechanical behaviour

• Electrical behaviour

• Safety against persons touching electically live parts

• Ability to meet the specific railway environmental conditions

• Use of appropriate tools

• Etc

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 33: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

İn order to prevent temperature rise at terminal points, the following measures shall be taken:

• Washers shall not be used between the conducting components

• Bolts shall not be used as conductors

• The metal surface materials of the two parts shall match and shall be cleaned and prepared

• When cable lugs are used the construction shall be such as to ensure the flow of current

– With a maximum of 2 contact interfaces at each bolted connection for power connections

– With a maximum of 4 contact interfaces at each bolted connection for control and protective earthing connections.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 34: Raiway applications rolling stock rules for installation of wire harness

Technical Requirements

2.17 Use of heat-shrinkable Sleeves

Head shrinkable sleeves may be used on railway equipment for two purposes

• For identification (by their colour or by carrying the marking itself, or by keeping extra markings in place)

• For electrical and mechanical protection (e.g. Prevention of water ingress and permanently maintaining a particular clearance or creepage).

2.18 Connetions for Return Current

The requirements of EN 50153 shall be fulfilled.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 35: Raiway applications rolling stock rules for installation of wire harness

3. EMC Requirements

3.1 General

The requirements specified in Clause 6 are based on the assumption that the car body is conductive. Whwn the car body consists of non conductive materials, more stringent measures are necessary to achieve EMC.

Cables are exposed to electromagnetic interference and they can also act as an interference source.

The requirements of EN 50121 shall be fullfield In order to ullfield EN 50121 the following cabling requirements should be fulfilled to the greatest possible extent.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 36: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

3.2 Cable Categories

Cable categories with respect to EMC

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

EMC Cable Category Duty of Cable

A

Power supply cables: Motor cables, braking resistor cables, heating supply cables, cables to line filters (on inverter side), auxiliary equipment

supply cables, combustion motor starter cables, etc.

B Battery lines, binary control lines, etc.

C Lines to signal transmitters, antenna lines loudspeaker lines,

databus lines, etc.

Page 37: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

3.3 Separation of Cables

Cables of different categories should be laid separately wherever possible. The required distance between cbles or cable bundles is in theory dependent on power, frequency components, length of parallel laying and immunity against emission. For practical purposes, the minumum distances in air between the cables in different cable categories shall be chosen according to table.

Minimum distances between cables of different EMC categories

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

EMC Cable Categories Separation Distance (m)

A and B 0,1

A and C 0,2

B and C 01

Page 38: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

3.4 Return Conductor

The feed and the return cables of a circuit shall be laid as close together as practicable, in particular in the case of power cables emitting disturbances, and sensitive signal cables. Twisted cables or cores should be used for this purpose, where available and practicable.

3.5 Use of Conductive Structure

Cables shall be installed as close as possible to conductive vehicle structures (metalic vehicle body plates, metalic cable ducts, metalic tubes, etc., connected to the vehicle body by means of conductive connection) to make maximum use of the reduction effect resulting from the cancellation of the field from the cable by the opposite field reflected from the metal surface.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 39: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

3.6 Shielding and Earthing

Cables of category A may be shielded, in order to reduce emissions. If not otherwise

Recommended by sub system manufacturer, cables of category C shall be shielded, in order to increase immunity. In cases where high levels of electromagnetic disturbance are expected, cables of all categories should be shielded.

Where screens are connected to earth, this should be done over as wide an area as possible. Connections where the screen is brought down to a single wire and extended through a connector pin to an earth point should not be used where other practical solutions are possible.

In general, the screen of a cable should be connected to earth as often as possible, and at least at both ends.

An earthing strategy should be drawn up to ensure that higher compensating or return currents due to voltage differences between the screen earthing points, do not flow through the screens.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 40: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

3.7 Supply Connection From Battery

Separate cables from the battery should be employed for the battery side supply of components with pulse shaped or pulse controlled load, where this is necessary. The branch off from the other supply cables should then be situated as close to the battery as possible.

3.8 Databus Lines

Databus lines should always be routed through dedicated plug connectors. Exceptions should only be made where there is no other physical solution (e.g. İn vehicle couplers).

Diffirent databus lines may be routed through a common plug connector. The databus cores shall then be assigned to the plug connector pins in such a manner that the greatest possible separation is achieved between the different databus lines.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 41: Raiway applications rolling stock rules for installation of wire harness

EMC Requirements

Interruption of databus lines represents an opening in the screen and causes unbalance in the signal symmetry. Databus lines should therefore be routed without interruption from device to device, i.e. The use of terminals and plugs should be avoided as far as possible. The sub system manufacturer may specify exceptions from these rules.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 42: Raiway applications rolling stock rules for installation of wire harness

4. Marking

4.1 General

This clause specifies marking additional to type marking on cables or equipment, in order to identify a particular piece of cable or equipment as being responsible for a certain function.

The method of marking of cables, cores and connectors etc. Should be changeable. The marking itself shall be permanent and easily legible. The information contained in the marking shall be in accordance with the documentation (circuit diagrams, wiring lists etc., as appropriate).

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 43: Raiway applications rolling stock rules for installation of wire harness

Marking

4.2 Marking of Cables

Cables and/or the individual cores installed in the vehicle including spares shall be marked for identification at all terminals and other detachable points in a practical way.

Individual cores in a multi core cable may be un marked if the cable is marked in accordance with the documentation (circuit diagrams, wiring lists etc., as appropriate)

And if the individual cores are identifiable by insulation colours or numbers etc. on thecore insulation, or by configuration.

Examples of cable or plug constructions where identification is done by configuration

(colours of core insulation: RD = red, GN = green, BK = black)

HAMDİ TOSUN

Senior Electrical System Design and Wire Harness Design Engineer

Page 44: Raiway applications rolling stock rules for installation of wire harness

Marking

4.3 Marking of Terminal Blocks, İndividual Terminals, Plugs and Sockets, Busbars

All terminal blocks shall be marked for identification, if there is any possibility of confusion. Marking shall be placed on the block, adjacent to it or on the cover on it.

The individual terminals on the terminal block shall be numbered.

All plug/socket devices should be marked for identification, if possible and if there is any possibility of confusion.

4.4 Marking of İnsulators

Insulators may not be marked for identification, but shall be identifiable documentation. The marking if any may be placed in the vicinity of the insulators.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 45: Raiway applications rolling stock rules for installation of wire harness

Marking

4.5 Marking for Warning Against Electrical Shock

Live parts of conducting elenents to which operation or maintenance staff may have access shall be indicated by warning labels accordingly.

Refer to EN 50153 and EN 61310-1

4.6 Marking using heat shrinkable sleeves

İf the marking is by heat shrinkable sleeves, the test described in Annex H shall be used for demonstrating the quality of the marking.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 46: Raiway applications rolling stock rules for installation of wire harness

5. Testing

5.1 General Concerning Testing

After installation, the completed cabling shall be tested by routine tests. Any components tests cable type tests included should be completed before this testing starts.

Concerning testing of cabling on rolling stock, EN 50215 specifies the following items:

• Cbale lenths ( EN 50215, concerned appropriate length for bogie nd inter car connections)

• Electric insulation tests (EN 50215). The concerned routine tests shall show that the cabling has been installed and finished correctly. Being free from damege to insulation materials. It is not intended to test the installed equipment or the cable material, since this is expected to have been tested before, during their manufacturing

• Earthing circuits (EN 50215)

• Train control circuits (EN 50215)

• Traction systems (EN 50215)

• Safety related systems (EN 50215)

• EMC (EN 50215)

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 47: Raiway applications rolling stock rules for installation of wire harness

Testing

5.2 Electrical İnsulation Tests

The objective is to test the insulation integrity of the vehicle electrical circuits.

5.2.1 General

The voltage withstand tests according may be carried out not on the completed vehicle, but upon completion of the cabling, after mounting and before connection of electrical aquipment already tested individually for dielectric strength. In this case the insulation impedance test according shall be carried out once the vehicle has been entirely completed.

If an insulation impedance test is carried out both before and after the voltage withstand test, the conditions shall be the same during both insulation impedance tests, and the impedance value measured by the test following the voltage withstand test shall be within 10% of those measured in the initial test.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 48: Raiway applications rolling stock rules for installation of wire harness

Testing

5.2.2 Voltage Withstand Test

a) Testing by alternating current (50Hz a.c)

Testing should preferably be performed with 50 Hz a.c. rms. If the circuits to be tested contain diodes or capacitors, the appropriate d.c. Voltage value shall be used.

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 49: Raiway applications rolling stock rules for installation of wire harness

Testing

b) Testing by impulse voltage

Test voltages according to on board voltages

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Noninal on board voltage (d.c. or a.c. Effective, conductor to earth)

Test voltage a.c. 50 Hz Impulse voltage (1,2/50 us acc. To HD 588.1 S1)

Up to 36 500 1000

Up to 72 750 1500

Up to 120 1000 2000

Up to 240 1500 3000

Up to 360 2000 4000

Over 360 (2,5 Un + 2000)*0,85 Up*2

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Testing

Nominal supply line voltage Test voltage a.c. 50 Hz Impulse test voltage (1,2/50 us acc. To HD 588.1 S1)

0,75 d.c 3,3 6,5

1,5 d.c 4,9 10

3 d.c 8,1 20

15 a.c 34 65

25 a.c 55 110

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Test voltages according to supply line voltages

If voltage withstand tests are repeated, the test voltage should be reduced by 20% of orginal voltage for each new test, in order not to destroy insulation.

Page 51: Raiway applications rolling stock rules for installation of wire harness

Testing

5.2.3 Insulation İmpedance test

Test limits

İf no values are agreed between manufacturer and purchaser, the test voltages shall be 500 V d.c. and the minimum insulation impedance values measured shall not be less than those given bellow.

• 5 M ohm for circuits having a rated voltage equal to or greater than 300 V d.c. or 100 V a.c.

• 1 ohm for circuits having a rated voltage less than 300 V d.c or 100 V a.c

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Page 52: Raiway applications rolling stock rules for installation of wire harness

Testing

Modification factor k1

Referance ambient temperature T ref = 45c

HAMDİ TOSUN Senior Electrical System Design and Wire

Harness Design Engineer

Cable type Expected ambient temperature T c

35 45 55 65 75 85 95 105 115 125 135 145

k1 for Tc(max) = 90c 1,11 1 0.88 0,75 0,58 0,33 - - - - - -

k1 for Tc(max) = 105c 1,08 1 0,91 0,82 0,71 0,58 0,41 - - - - -

k1 for Tc(max) = 120c 1,06 1 0,93 0,86 0,77 0,68 0,58 0,45 0,26 - - -

k1 for Tc(max) = 140c 1,05 1 0,95 0,89 0,83 0,76 0,69 0,61 0,51 0,40 0,23 -

k1 for Tc(max) = 150c 1,05 1 0,95 0,90 0,85 0,79 0,72 0,65 0,58 0,49 0,38 0,22

Page 53: Raiway applications rolling stock rules for installation of wire harness

Thank You For Your Attention

HAMDİ TOSUN Senior Electrical System Design and

Wire Harness Design Engineer