BMT1B 01 01 00 A1

Volume I: Technical Manual BMRCL - Rolling Stock
Part B: Technical Descriptions of Equipment Systems Revision No: A0

Chapter 1: Vehicle Date: 18-04-2011
Page: 1B-01-00-00-01
BMRCL Rolling Stock

Operation and Maintenance Manual
Volume I: Technical Manual

Part B: Technical Descriptions of Equipment Systems
Chapter 1: Vehicle
BMRCL - Rolling Stock Volume I: Technical Manual
Revision No: A0 Part B: Technical Descriptions of Equipment Systems
Date: 18-04-2011 Chapter 1: Vehicle
Page: 1B-01-00-00-02
Revision Record
This page is provided for the recording of any amendment to this document. If
amended pages are issued, the following procedure must be followed:
(a) Incorporate the revised pages in accordance with amendment instructions issued
with the amendment.
(a) Dispose of any pages removed in accordance with the amendment instructions.
(b) Record the incorporation of the amendments by completing the appropriate
boxes in the Revision Record below.
Revision No. Date of Insertion Inserted By
Page: 1B-01-00-00-03
Chapter Contents
Section 1.1 Cabling

Section 1.2 Piping
Section 1.3 Junction Boxes
Section 1.4 Relay Panel
Section 1.5 Electrical Distribution Board
Section 1.6 MCB Panel 1
Section 1.7 MCB Panel 2
Section 1.8 DC-DC Converter
Page: 1B-01-00-00-04
THIS PAGE INTENTIONALLY LEFT BLANK

Page: 1B-01-00-00-05
Contents
Page
Section 1B-01-01-00: Cabling........................................................... 1B-01-01-00-01

1 Overall Description..................................................................... 1B-01-01-00-01
2 High Tension Cable .................................................................... 1B-01-01-00-01
2.1 Overall Description ....................................................................... 1B-01-01-00-01
2.2 Cross section of cable .................................................................. 1B-01-01-00-04
2.3 Design and Performance Data...................................................... 1B-01-01-00-04
2.3.1 High Tension Power Cable .............................................. 1B-01-01-00-04
2.3.2 High Tension Power Cable, Flexible ................................ 1B-01-01-00-04
3 Low Tension Cables................................................................... 1B-01-01-00-05

3.2 Equipment Layouts ....................................................................... 1B-01-01-00-06
4 Signal Cables .............................................................................. 1B-01-01-00-07

4.1 Unshielded Cables........................................................................ 1B-01-01-00-07
4.1.1 Overall Description .......................................................... 1B-01-01-00-07
4.1.2 Equipment Layouts .......................................................... 1B-01-01-00-07
4.1.3 Design and Performance Data......................................... 1B-01-01-00-08
4.2 Shielded Cables ........................................................................... 1B-01-01-00-08
4.3 Fire Resistant Cables ................................................................... 1B-01-01-00-11
4.4 Data Transmission Cable.............................................................. 1B-01-01-00-14
4.4.2 Equipment Layout............................................................ 1B-01-01-00-14
5 Cable Duct................................................................................... 1B-01-01-00-16

Page: 1B-01-00-00-06
Contents (cont.)
Page
6 Flexible Conduits........................................................................ 1B-01-01-00-19

7 Terminals.....................................................................................1B-01-01-00-22
8 Connectors.................................................................................. 1B-01-01-00-24
8.1 MS Connectors............................................................................. 1B-01-01-00-24
8.2 FCI Connector, 59 Pin .................................................................. 1B-01-01-00-27
8.3 FCI Connector, 24 Pin and 36 Pin ................................................ 1B-01-01-00-30
8.4 Harting Connector (42P, 72P)....................................................... 1B-01-01-00-33
8.4.2 Equipment Layout............................................................ 1B-01-01-00-33
8.5 Terminal Block.............................................................................. 1B-01-01-00-34
9 Accessories ................................................................................ 1B-01-01-00-35

9.1 Cable Harness Connectors, EMC ................................................. 1B-01-01-00-35
Page: 1B-01-00-00-07
Contents (cont.)
Page
9.2 Lock Nuts ..................................................................................... 1B-01-01-00-37
9.3 Cable Glands................................................................................ 1B-01-01-00-39
Sub-section 1B-01-02-00: Overall .................................................... 1B-01-02-00-01

Sub-section 1B-01-02-01: Piping Arrangement .............................. 1B-01-02-01-01
2 Equipment Layouts .................................................................... 1B-01-02-01-02
3 Design and Performance Data................................................... 1B-01-02-01-14
Sub-section 1B-01-02-02: Flexible Hose Arrangement .................. 1B-01-02-02-01
2 Equipment Locations ................................................................. 1B-01-02-02-02
4 Design and Performance Data................................................... 1B-01-02-02-14
Section 1B-01-03-00: Junction Boxes ............................................. 1B-01-03-00-01
1 Technical Description ................................................................ 1B-01-03-00-01
1.1 Jumpers........................................................................................ 1B-01-03-00-01
1.1.1 Jumper arrangement for 3 car train composition.............. 1B-01-03-00-01
1.1.2 General Description of Jumpers....................................... 1B-01-03-00-01
1.1.3 Description of low tension jumpers (3P, 11P, 27P, 74P, Odometer)..........
........................................................................................ 1B-01-03-00-02
1.1.4 Description of the high tension jumpers (1P).................... 1B-01-03-00-02
1.2 Junction Boxes ............................................................................. 1B-01-03-00-03
1.2.1 Description of the low tension junction box ...................... 1B-01-03-00-03
1.2.2 Description of the high tension junction plate ................... 1B-01-03-00-03
Page: 1B-01-00-00-08
Contents (cont.)
Page
1.2.3 Description of the Collector Shoe junction box................. 1B-01-03-00-04
1.2.4 Description of the Traction Motor (T/M) Connector .......... 1B-01-03-00-05
1.2.5 Description of the Speed Sensor Connector .................... 1B-01-03-00-05
2 Specification of Components .................................................... 1B-01-03-00-06

2.1 Connectors of the low tension jumpers & junction box .................. 1B-01-03-00-06
2.2 Connectors of the High tension jumper & junction plate................ 1B-01-03-00-08
2.3 Connectors of the Speed Sensor .................................................. 1B-01-03-00-09
2.4 Connectors of the T/M Junction Plate ........................................... 1B-01-03-00-10
2.5 Ratings and Standard ................................................................... 1B-01-03-00-10
Section 1B-01-04-00: Relay Panel .................................................... 1B-01-04-00-01

1 Description of Relay Panel ........................................................ 1B-01-04-00-01
2.1 Relay (D8-U204)........................................................................... 1B-01-04-00-02
2.2 Relay (D-U204)............................................................................. 1B-01-04-00-03
2.3 Relay (TNL**ERT-DC110V).......................................................... 1B-01-04-00-04
2.4 Timer Relay .................................................................................. 1B-01-04-00-05
2.5 Contactor (TAL40, TAL9).............................................................. 1B-01-04-00-06
2.6 Relay (C009, C027) ...................................................................... 1B-01-04-00-06
Section 1B-01-05-00: Electrical Distribution Board........................ 1B-01-05-00-01

1 Description of the Electrical Distribution Board (EDB)........... 1B-01-05-00-01
2.1 Relay (D8-U204)........................................................................... 1B-01-05-00-02
2.2 Relay (D-U204)............................................................................. 1B-01-05-00-03
2.3 Relay (TNL**ERT-DC110V).......................................................... 1B-01-05-00-04
2.4 Timer Relay .................................................................................. 1B-01-05-00-05
2.5 Contactor(TAL40, TAL9)............................................................... 1B-01-05-00-06
2.6 Miniature Circuit Breaker (C60H- DC)........................................... 1B-01-05-00-07
2.7 Miniature Circuit Breaker (DPN N VIGI-19666) ............................. 1B-01-05-00-08
2.8 Miniature Circuit Breaker (C60N) .................................................. 1B-01-05-00-09
Section 1B-01-06-00: MCB Panel 1 .................................................. 1B-01-06-00-01

1 Description of the Miniature Circuit Breaker Panel 1 (MCB Panel 1). 1B-01-06-00-01
Page: 1B-01-00-00-09
Contents (cont.)
Page
2.1 Miniature Circuit Breaker (C60H- DC)........................................... 1B-01-06-00-02
Section 1B-01-07-00: MCB Panel 2 .................................................. 1B-01-07-00-01

1 Description of the Miniature Circuit Breaker panel 2 (MCB panel 2) . 1B-01-07-00-01
Section 1B-01-08-00: DC-DC Converter........................................... 1B-01-08-00-01

1 Equipment Locations ................................................................. 1B-01-08-00-01
2 Equipment Functions................................................................. 1B-01-08-00-01
3 System Controls ......................................................................... 1B-01-08-00-01
Page: 1B-01-00-00-10
Illustrations
Fig. Page
Fig. 1B-01-01-00-01 750V DC System ................................................... 1B-01-01-00-03
Fig. 1B-01-01-00-02 Layout of High Tension Cable................................ 1B-01-01-00-04
Fig. 1B-01-01-00-03 Layout of Low Tension Cable ................................ 1B-01-01-00-06
Fig. 1B-01-01-00-04 Layout of 1-Core Unshielded Cable ...................... 1B-01-01-00-07
Fig. 1B-01-01-00-05 Layout of Multi-Core Unshielded Cable.................. 1B-01-01-00-07
Fig. 1B-01-01-00-06 Layout of Multi-Core Shielded Cable ..................... 1B-01-01-00-09
Fig. 1B-01-01-00-07 Layout of Fire Resistant Cable............................... 1B-01-01-00-11
Fig. 1B-01-01-00-08 Specifications of Fire Resistant Cables.................. 1B-01-01-00-13
Fig. 1B-01-01-00-09 Layout of Data Transmission Cable ....................... 1B-01-01-00-14
Fig. 1B-01-01-00-10 Characteristic of Databus 100Ω2x0.75 .................. 1B-01-01-00-15
Fig. 1B-01-01-00-11 "DMC" car cable containment Layout..................... 1B-01-01-00-17
Fig. 1B-01-01-00-12 "TC" car cable containment Layout........................ 1B-01-01-00-18
Fig. 1B-01-01-00-13 Composite Harness Assembly............................... 1B-01-01-00-19
Fig. 1B-01-01-00-14 Layout of Flexible Conduit ..................................... 1B-01-01-00-20
Fig. 1B-01-01-00-15 Terminal Lug.......................................................... 1B-01-01-00-22
Fig. 1B-01-01-00-16 Layout of Terminal Lug .......................................... 1B-01-01-00-22
Fig. 1B-01-01-00-17 Layout of RFI Connector Receptacle ..................... 1B-01-01-00-25
Fig. 1B-01-01-00-18 Layout of RFI Connector Plug................................ 1B-01-01-00-25
Fig. 1B-01-01-00-19 Insert Arrangements .............................................. 1B-01-01-00-26
Fig. 1B-01-01-00-20 FCI Connector Plug, 59 Pin ................................... 1B-01-01-00-28
Fig. 1B-01-01-00-21 FCI Connector Receptacle, 59 Pin......................... 1B-01-01-00-29
Fig. 1B-01-01-00-22 24 Pin Connector Plug and Receptacle ................. 1B-01-01-00-30
Fig. 1B-01-01-00-23 36 Pin Connector Plug and Receptacle ................. 1B-01-01-00-30
Fig. 1B-01-01-00-24 FCI Non-Fixed Rectangle Type Connector Plug .... 1B-01-01-00-31
Fig. 1B-01-01-00-25 FCI Non-Fixed Rectangle Type Connector Receptacle...................
.............................................................................. 1B-01-01-00-32
Fig. 1B-01-01-00-26 Harting Connector (Plug and Receptacle).............. 1B-01-01-00-33
Fig. 1B-01-01-00-27 3-conductor Through Terminal Block (279-681)..... 1B-01-01-00-34
Fig. 1B-01-01-00-28 Cross section and dimension details of EMC Connector, Female ...
.............................................................................. 1B-01-01-00-35
Fig. 1B-01-01-00-29 Cross section and dimension details of EMC Connector Male ........
.............................................................................. 1B-01-01-00-36
Fig. 1B-01-01-00-30 Lock Nut ................................................................ 1B-01-01-00-37
Fig. 1B-01-01-00-31 Layout of Lock Nut................................................. 1B-01-01-00-37
Fig. 1B-01-01-00-32 Cable Gland .......................................................... 1B-01-01-00-39
Page: 1B-01-00-00-11
Illustrations (cont.)
Fig. Page
Fig. 1B-01-01-00-33 Layout of Cable Gland ........................................... 1B-01-01-00-39
Fig. 1B-01-02-01-01 DMC Piping Layout................................................ 1B-01-02-01-04
Fig. 1B-01-02-01-02 TC Piping Layout ................................................... 1B-01-02-01-10
Fig. 1B-01-02-02-01 DMC Flexible Hose Arrangement .......................... 1B-01-02-02-04
Fig. 1B-01-02-02-02 TC Flexible Hose Arrangement.............................. 1B-01-02-02-09
Fig. 1B-01-02-02-03 Auto Coupler Flexible Hose Arrangement.............. 1B-01-02-02-11
Fig. 1B-01-02-02-04 Semi-permanent Coupler Flexible Hose Arrangement ....................
.............................................................................. 1B-01-02-02-12
Fig. 1B-01-02-02-05 BC-PB Flexible Hose Arrangement........................ 1B-01-02-02-13
Fig. 1B-01-02-02-06 CM Flexible Hose Arrangement ............................. 1B-01-02-02-13
Fig. 1B-01-02-02-07 ACM Flexible Hose Arrangement........................... 1B-01-02-02-13
Fig. 1B-01-02-02-08 Hose Air ACM........................................................ 1B-01-02-02-14
Fig. 1B-01-03-00-01 Configuration of the Low Tension Jumper.............. 1B-01-03-00-02
Fig. 1B-01-03-00-02 Configuration of the High Tension Jumper............. 1B-01-03-00-02
Fig. 1B-01-03-00-03 Configuration of the Low Tension Junction Box ..... 1B-01-03-00-03
Fig. 1B-01-03-00-04 Configuration of the High Tension Junction Plate .. 1B-01-03-00-03
Fig. 1B-01-03-00-05 Configuration of the Collector Shoe Junction Box .. 1B-01-03-00-04
Fig. 1B-01-03-00-06 Configuration of the Traction Motor(T/M) Connector .......................
.............................................................................. 1B-01-03-00-05
Fig. 1B-01-03-00-07 Configuration of the Speed Sensor Connector....... 1B-01-03-00-05
Fig. 1B-01-03-00-08 Recommended Current according to the Temperature ...................
.............................................................................. 1B-01-03-00-11
Fig. 1B-01-04-00-01 Layout of Relay Panel............................................ 1B-01-04-00-01
Fig. 1B-01-04-00-02 Configuration of Relay (D8-U204).......................... 1B-01-04-00-02
Fig. 1B-01-04-00-03 Configuration of Relay (D-U204)............................ 1B-01-04-00-03
Fig. 1B-01-04-00-04 Configuration of Relay (TNL**ERT) ....................... 1B-01-04-00-04
Fig. 1B-01-05-00-01 Lay out of Electrical distribution board(EDB).......... 1B-01-05-00-01
Fig. 1B-01-05-00-02 Configuration of Relay (D8-U204).......................... 1B-01-05-00-02
Fig. 1B-01-05-00-03 Configuration of Relay (D-U204)............................ 1B-01-05-00-03
Fig. 1B-01-05-00-04 Configuration of Relay (TNL**ERT) ....................... 1B-01-05-00-04
Fig. 1B-01-05-00-05 Miniature Circuit Breaker (C60H-DC)..................... 1B-01-05-00-07
Fig. 1B-01-05-00-06 Miniature Circuit Breaker (DPN N VIGI-19666) ...... 1B-01-05-00-08
Fig. 1B-01-06-00-01 Layout of Miniature Circuit Breaker Panel 1 (MCB Panel 1)............
.............................................................................. 1B-01-06-00-01
Fig. 1B-01-06-00-02 Miniature Circuit Breaker (C60H-DC)..................... 1B-01-06-00-02
Page: 1B-01-00-00-12
Illustrations (cont.)
Fig. Page
Fig. 1B-01-07-00-01 Layout of Miniature Circuit Breaker Panel 2 (MCB Panel 2)............
.............................................................................. 1B-01-07-00-01
Fig. 1B-01-08-00-01 DC-DC Converter Layout....................................... 1B-01-08-00-02
Page: 1B-01-00-00-13
Tables
Table No. Page
Table 1B-01-01-00-01 List of High Tension Cables ................................... 1B-01-01-00-02
Table 1B-01-01-00-02 Specifications of High Tension Cables................... 1B-01-01-00-04
Table 1B-01-01-00-03 Specifications of High Tension Cables, Flexible..... 1B-01-01-00-05
Table 1B-01-01-00-04 List of Low Tension Cables.................................... 1B-01-01-00-05
Table 1B-01-01-00-05 Specifications of Low Tension Cables ................... 1B-01-01-00-06
Table 1B-01-01-00-06 List of Unshielded Cables ...................................... 1B-01-01-00-07
Table 1B-01-01-00-07 Specifications of Unshielded Cables...................... 1B-01-01-00-08
Table 1B-01-01-00-08 List of shielded Cables........................................... 1B-01-01-00-08
Table 1B-01-01-00-09 Specifications of Shielded Cables.......................... 1B-01-01-00-10
Table 1B-01-01-00-10 List of Fire Resistant Cables .................................. 1B-01-01-00-11
Table 1B-01-01-00-11 List of Data communication Cables........................ 1B-01-01-00-14
Table 1B-01-01-00-12 Specifications of Flexible Conduits ........................ 1B-01-01-00-20
Table 1B-01-01-00-13 Specifications of Terminal Lugs ............................. 1B-01-01-00-23
Table 1B-01-01-00-14 List of MS Connector ............................................. 1B-01-01-00-24
Table 1B-01-01-00-15 Specifications of RFI Connector Receptacles ........ 1B-01-01-00-25
Table 1B-01-01-00-16 Specifications of RFI Connector Plugs................... 1B-01-01-00-26
Table 1B-01-01-00-17 Contact and Wire Sizes ......................................... 1B-01-01-00-27
Table 1B-01-01-00-18 FCI Connector Plug, 59 Pin Material...................... 1B-01-01-00-28
Table 1B-01-01-00-19 FCI Connector Receptacle, 59 Pin Material ........... 1B-01-01-00-29
Table 1B-01-01-00-20 Specifications of 24 Pin and 36 Pin Plugs.............. 1B-01-01-00-31
Table 1B-01-01-00-21 Specifications of 24 Pin and 36 Pin Receptacles ... 1B-01-01-00-32
Table 1B-01-01-00-22 Specifications of EMC Female Connectors............ 1B-01-01-00-36
Table 1B-01-01-00-23 Specifications of EMC Male Connectors ................ 1B-01-01-00-36
Table 1B-01-01-00-24 Specifications of Lock Nuts.................................... 1B-01-01-00-38
Table 1B-01-01-00-25 Specifications of Cable Glands .............................. 1B-01-01-00-39
Table 1B-01-03-00-01 Contact ratings according to Pin size (refer to Fig. 1B-01-03-00-08)
.............................................................................. 1B-01-03-00-10
Table 1B-01-03-00-02 Service ratings....................................................... 1B-01-03-00-11
Table 1B-01-03-00-03 Dielectric standard................................................. 1B-01-03-00-11
Table 1B-01-04-00-01 Design Data of Relay Panel................................... 1B-01-04-00-02
Table 1B-01-04-00-02 Specification of Relay (D8-U204)........................... 1B-01-04-00-02
Table 1B-01-04-00-03 Specification of Relay (D-U204)............................. 1B-01-04-00-03
Table 1B-01-04-00-04 Specification of Relay (TNL**ERT) ........................ 1B-01-04-00-04
Table 1B-01-04-00-05 Specifications of Time Relay (CT-MVS-**)............. 1B-01-04-00-05
Page: 1B-01-00-00-14
Tables (cont.)
Table No. Page
Table 1B-01-04-00-06 Specifications (TAL9,TAL40) ................................. 1B-01-04-00-06
Table 1B-01-04-00-07 Specification of Relay (C009, C027) ...................... 1B-01-04-00-06
Table 1B-01-05-00-01 Design Data of Electrical distribution board(EDB).. 1B-01-05-00-02
Table 1B-01-05-00-02 Specification of Relay (D8-U204)........................... 1B-01-05-00-02
Table 1B-01-05-00-03 Specification of Relay (D-U204)............................. 1B-01-05-00-03
Table 1B-01-05-00-04 Specification of Relay (TNL**ERT) ........................ 1B-01-05-00-04
Table 1B-01-05-00-05 Specifications of TIME RELAY (CT-MVS-**).......... 1B-01-05-00-05
Table 1B-01-05-00-06 Specifications (TAL9, TAL40) ................................ 1B-01-05-00-06
Table 1B-01-05-00-07 Specification of MCB (C60H-DC)........................... 1B-01-05-00-07
Table 1B-01-05-00-08 Specification of MCB (C60N-DC)........................... 1B-01-05-00-09
Table 1B-01-06-00-01 Design Data of Miniature Circuit Breaker Panel 1 (MCB Panel 1) ...
.............................................................................. 1B-01-06-00-01
Table 1B-01-06-00-02 Specification of MCB (C60H-DC)........................... 1B-01-06-00-02
Table 1B-01-07-00-01 Design Data of Miniature Circuit Breaker Panel 2 (MCB Panel 2) ...
.............................................................................. 1B-01-07-00-01
Table 1B-01-08-00-01 DC-DC Converter Components ............................. 1B-01-08-00-02
Section 1.1: Cabling
Page: 1B-01-01-00-01
Section 1B-01-01-00: Cabling
1 Overall Description
Cabling is used as the means of electrically connecting the various equipments of the
train. The electric devices are classified as high voltage or low voltage depending
upon the supplied voltage as follows:
(a) High voltage: DC750V
(b) Low voltage: under 750 V:
(i) 415V, 50Hz, 3Ø AC / 230 V, 50Hz, 1Ø AC.
(ii) 110V DC.
(iii) Signal.
Therefore, two kinds of cable are provided to electrically connect the various equipment.
The electrical wiring harness has various combinations of connectors and other
components for the numerous wiring applications on the train.
The cable harnesses perform the role to electrically interconnect the operating
components of the train. Within the harnesses, the cable surfaces are covered with
protective tubes. The cable ends are then connected with connectors or other joining
components.
The primary purpose of the harness assemblies is to guarantee electrical performance
by ensuring that cables are not exposed.
The cable used in the train has features of optimum area to carry current and high
flexibility. Each cable is colour coded to provide identification of each core during the
connection of cable assemblies.
Twisted pair core is utilised to minimise mutual interference from adjacent circuits.
Some cables are covered with a copper shield for protection from high frequency
external interference.
2 High Tension Cable

2.1 Overall Description
The purpose of the High Voltage System is to transmit the energy from the 3rd rail
current collect system to the vehicle and distribute it to the propulsion and auxiliary
systems.
The high voltage system is located in the underframe and in the bogie of the vehicle.
Each vehicle has its own high voltage equipment.
In positions where vibration occurs, e.g. the Current Collector, Earth Brush, High
Voltage Jumper coupler, 4GKW-AX-J-185 series flexible cable is used.
Page: 1B-01-01-00-02
Table 1B-01-01-00-01 List of High Tension Cables
Voltage Rating
No Name of Cable Application Remarks
(U0 / U)
1 4GKW-AX-35 U0 : Rated
voltage
2 4GKW-AX-70 between
1800/3000VAC,
3 4GKW-AX-95 High Voltage Power 2250/4500VDC, conductor
120°C and earth
4 4GKW-AX-150
5 4GKW-AX-185
U : Rated
Flexible Wiring Connection voltage
1800/3000VAC,
(Current Collector, Earth between
6 4GKW-AX-J-185 2700/4500VDC,
Brush, High Voltage Conductors
90°C
Jumper coupler)
The code of part number given above can be interpreted as under.
E.g. 4 G K W – A X - J - 185
⑥ ⑦ ⑧
① Type designation
② G : RADOX GKW insulation
③ K : cold resistant
④ W : heat resistant
⑤ A : RADOX GKW sheath, oil resistant
⑥ X : crosslinked polyolefin
⑦ J : flexibility
⑧ Conductor size (mm2)

Page: 1B-01-01-00-03
Fig. 1B-01-01-00-01 750V DC System

Page: 1B-01-01-00-04
2.2 Cross section of cable
1 Conductor, standed tin coated copper (IEC 228 Class 5).

2 Insulation, Radox GKW K copolymer.
3 Sheath, Radox GKW S copolymer, Colour : black.
Fig. 1B-01-01-00-02 Layout of High Tension Cable
2.3 Design and Performance Data

2.3.1 High Tension Power Cable
No Wire & Cable Name Part No. Remarks

Single core cable, Halogen Free
1 1800/3000Volt AC, 2250/4500Volt DC, 4GKW-AX-**
120°C
Table 1B-01-01-00-02 Specifications of High Tension Cables
Cable Conductor Wall Cable-D R20 CH20** Weight

Fire load
type construction* dia nom min Dnom max nom copper cable
kJ/m
㎟ n×㎜㎜㎜㎜ Ω /㎞㎊/m ㎏ / 100m
35 266 x 0.41 7.80 ± 0.25 1.50 11.7 ± 0.30 0.565 490 1564 31 39
70 348 x 0.51 11.5 ± 0.35 1.70 15.6 ± 0.30 0.277 645 2504 61 74
95 444 x 0.51 12.9 ± 0.40 1.90 17.3 ± 0.30 0.210 665 2734 80 96
150 722 x 0.51 16.8 ± 0.50 2.20 21.9 ± 0.30 0.132 720 4035 127 155
185 874 x 0.51 18.5 ± 0.55 2.30 23.8 ± 0.30 0.108 770 4733 154 188
* (Typical value x single wire diameter)
** (Capacity in water typical value)
2.3.2 High Tension Power Cable, Flexible

Current
Single core cable, Halogen Free,
Collector, Earth
1 Very Flexible 1800/3000Volt AC, 4GKW-AX-J-**
Brush, High
2700/4500Volt DC, 90°C
Voltage Jumper
Page: 1B-01-01-00-05
Table 1B-01-01-00-03 Specifications of High Tension Cables, Flexible
**
Cable Conductor Wall Cable-D R20 CH20 Weight
Fire load
type construction* dia nom min Dnom max nom copper cable
kJ/m
㎟ n×㎜㎜㎜㎜ Ω /㎞㎊/m ㎏ / 100m
1520 x
185 19.7 ± 0.55 2.35 25.0 ± 0.30 0.108 812 6344 177 210
0.41
3 Low Tension Cables

The purpose of the Low Voltage System is to transmit the energy from the auxiliary
power system to the vehicle and distribute it to the vehicle equipment and control
systems.
The low voltage system is located in the underframe and in the saloon area of the
vehicle. Each vehicle has its own low voltage and control equipment.
Table 1B-01-01-00-04 List of Low Tension Cables
Voltage Rating
(U0 / U)
1 3GKW-6 U0 : Rated
voltage between
2 3GKW-16
conductor and
3 3GKW-35 600/1000VAC, earth
Low Voltage Power 900/1500VDC,
4 3GKW-50 120°C
5 3GKW-70 U : Rated
voltage between
6 3GKW-95 Conductors
The code of part number given above can be interpreted as under.
E.g. 3 G K W – 185
Type designation
G : RADOX GKW insulation
K : cold resistant
W : heat resistant
Conductor size (mm2)
Page: 1B-01-01-00-06
3.2 Equipment Layouts
1 Conductor, flexible tin-plated copper.

2 Insulation, Radox GKW J, coloured grey.
Fig. 1B-01-01-00-03 Layout of Low Tension Cable

Single core cable, Halogen Free
1 600/1000Volt AC, 900/1500Volt DC, 3GKW-**
120°C
Table 1B-01-01-00-05 Specifications of Low Tension Cables
**
Cable Conductor Wall Cable-D R20 CH20 Fire load Weight
type construction* dia nom min Dnom max nom copper cable Colours
2
mm n × mm mm mm mm Ω / km ㎊/m kJ/m kg / 100m
grey
6.0 84×0.31 3.10±0.15 0.70 4.70±0.15 3.39 575 244 5.30 6.90
yellow green
grey
16 119×0.41 5.30±0.20 0.90 7.25±0.15 1.24 750 490 13.4 16.6
yellow green
grey
35 266×0.41 7.80±0.25 1.10 10.2±0.20 0.565 895 847 29.5 35.0
yellow green
grey
50 378×0.41 9.30±0.30 1.20 11.9±0.20 0.393 970 1040 42.5 49.5
yellow green
grey
70 348×0.51 11.4±0.35 1.30 14.3±0.25 0.277 1060 1350 59.2 68.0
yellow green
grey
95 444×0.51 12.8±0.40 1.40 15.9±0.25 0.210 1110 1600 79.5 90.0
yellow green

Page: 1B-01-01-00-07
4 Signal Cables
4.1 Unshielded Cables
4.1.1 Overall Description
Table 1B-01-01-00-06 List of Unshielded Cables
Voltage Rating
(U0 / U)
1 3GKW-1.5
Digital Input/Output Signal 600/1000 V AC, 3GKW-**
2 3GKW-2.5 900/1500Volt DC,
Small current Power & Signal 120°C
3 3GKW/S-2x1.5 3GKW/S-**
4.1.2 Equipment Layouts
1 Conductor, flexible tin-plated copper.

2 Insulation, Radox GKW J, coloured grey.
Fig. 1B-01-01-00-04 Layout of 1-Core Unshielded Cable
1 Conductor, flexible tin-plated copper, coloured grey

2 Fillers (optional)
3 Separators (optional)
4 Sheath, Radox GKW S, colour : black
Fig. 1B-01-01-00-05 Layout of Multi-Core Unshielded Cable

Page: 1B-01-01-00-08
4.1.3 Design and Performance Data

Table 1B-01-01-00-07 Specifications of Unshielded Cables
**
Cable Conductor Wall Cable-D R20 CH20 Fire load Weight
type construction* dia nom min Dnom max nom copper cable Colours
mm2 n × mm mm mm mm Ω / km ㎊/m kJ/m kg / 100m
grey
1.5 30×0.26 1.52±0.05 0.55 2.70±0.10 13.7 420 90 1.30 1.88
yellow green
grey
2.5 50×0.26 1.94±0.05 0.60 3.30±0.10 8.21 450 129 2.20 3.05
yellow green
2x grey
30 x 0.25 1.60 2.70 7.5 ± 0.3 13.7 120 840 2.7 8.6
1.5 yellow green

4.2 Shielded Cables

Table 1B-01-01-00-08 List of shielded Cables
Voltage Rating
(U0 / U)
GKW LW/S
4
EMC-2x1.0
GKW LW/S Analog Voltage
5 600/1000Volt AC,
EMC-3x0.5 Signal
900/1500Volt DC, GKW LW/S EMC-**
GKW LW/S Speed Signal 120°C
6
EMC-3x1.0 (Shield Cable)
GKW LW/S
7
EMC-4x1.0
The code of part number given above can be interpreted as under
E.g. G K W – LW/S EMC – n x 1.0
⑥ ⑦ ⑧
G : RADOX GKW insulation system
K : cold resistant
W : heat resistant
LW : Light Weight – Thin wall
S : Overall sheath
⑥ EMC : Shielded cable
⑦ Number of conductors
Page: 1B-01-01-00-09
⑧ Conductor size (mm2)

Page: 1B-01-01-00-10
1 Conductor, flexible tin plated copper, colour : white

2 Shield, tin-coated copper braid optimised.
3 Wrapping (optional), Plastic tape
4 Jacket, Radox GKW S, colour : black
Fig. 1B-01-01-00-06 Layout of Multi-Core Shielded Cable

Page: 1B-01-01-00-11

Table 1B-01-01-00-09 Specifications of Shielded Cables
Cable type Conductor Core-D Screen Cable-D R20 lK** ZT C Fire Weight
construction* Dnom Dnom Dmax size Dnom cond. Screen screen max core/core core/screen load copper cable
n x mm2 n x AWG n × mm mm mm mm mm2 mm Ω / km Ω / km A mΩ / m ㎊/m kJ/m kg / 100m
2 x 1.0 2 x 18 19 x 0.25 1.22 1.67 3.8 0.75 5.0 ± 0.3 20.0 25.9 235 200 125 215 270 2.5 5.0
3 x 0.50 - 19 x 0.18 0.90 1.30 3.3 0.75 4.5 ± 0.3 40.1 25.9 235 200 110 190 345 2.2 4.0
3 x 1.0 3 x 18 19 x 0.25 1.22 1.67 4.1 1.14 5.5 ± 0.3 20.0 18.6 345 150 125 215 305 3.8 6.0
4 x 1.0 4 x 18 19 x 0.25 1.22 1.67 4.5 1.04 5.8 ± 0.3 20.0 20.2 315 150 125 215 335 3.7 7.2
Page: 1B-01-01-00-12
4.3 Fire Resistant Cables

Fire resistant cables are used in the PA (public address) system circuit such as PA
AMP, speaker, PEA (Passenger Emergency Alarm), PAEH (Passenger Alarm
Emergency Handle).
Table 1B-01-01-00-10 List of Fire Resistant Cables

Single core cable, Halogen free, flame
1 retardant 600/1000Volt AC, 3GKW/S FR BS EMC 2x1.5
900/150Volt DC, 120°C
1 Conductor, tin-plated copper, Colour : grey, black numbered

2 Filler, Radox
3 Standard EMC-screen, Tin plated copper braid
4 Wrapping, Tape
5 Sheath, Radox EM 104, colour : black
Fig. 1B-01-01-00-07 Layout of Fire Resistant Cable

Page: 1B-01-01-00-13

Page: 1B-01-01-00-14
Fig. 1B-01-01-00-08 Specifications of Fire Resistant Cables

Page: 1B-01-01-00-15
4.4 Data Transmission Cable

Cable for symmetrical data transmission with impedance of 100Ω with very good
transmission properties at high frequencies.
Table 1B-01-01-00-11 List of Data communication Cables

Databus 100Ω, Halogen free
1 Databus 100Ω2x0.75 GKW/S
Excellent Screening Properties
4.4.2 Equipment Layout
1 Conductor, flexible tin-plated copper, Colour : white, red

2 Filler
3 Wrapping, Plastic tape
4 EMC-screen optimised, Tin plated copper braid
5 Sheath, GKW S, colour : black
Fig. 1B-01-01-00-09 Layout of Data Transmission Cable

Page: 1B-01-01-00-16
Fig. 1B-01-01-00-10 Characteristic of Databus 100Ω2x0.75

Page: 1B-01-01-00-17
5 Cable Duct
The cable containment ducting system is designated Cable duct for high voltage and
cable duct for low voltage. These High tension and Low tension ducts are divided
into 2~4 sections by the cable size and characteristics. The sections of each duct
included all kinds of cables and cable connection parts. The cabling is distributed in
a suitable form within the ducts depending upon the characteristic of the equipment
to which the cables are connected. The duct is fabricated from solid drawn
aluminium, A6063BE grade. All cable ducting is designed for a space factor of at
least 45%.
Page: 1B-01-01-00-18
Low Voltage cable ducts High Voltage cable ducts
Low Voltage cable ducts High Voltage cable ducts
Fig. 1B-01-01-00-11 "DMC" car cable containment Layout

Page: 1B-01-01-00-19
Low Voltage Cable ducts High Voltage Cable ducts
High Voltage Cable ducts Low Voltage Cable ducts
Fig. 1B-01-01-00-12 "TC" car cable containment Layout

Page: 1B-01-01-00-20
6 Flexible Conduits
In consideration of exposed external applications, such as the undercarriage on
railway vehicles, the train is installed with PMA-FLEX conduit type VCS that offers a
high degree of mechanical strength to protect cables.
A Connector Assembly (MS Connector + EMC Connector, female)

B EMC connector, male
C EMC connector, female
D Y-type distributor
E Corrugated conduit
Fig. 1B-01-01-00-13 Composite Harness Assembly

Page: 1B-01-01-00-21
Fig. 1B-01-01-00-14 Layout of Flexible Conduit
Table 1B-01-01-00-12 Specifications of Flexible Conduits
Specification Cable
Index
Part No. Part Name Bundle
No. NW PG D1 D2 R Size
1 VCST-10B 10 09 9.2 13.0 25 0-7
2 VCST-12B 12 11 11.8 15.8 30 7-9
Conduits
3 VCSG-17B externally 17 16 15.2 21.2 40 9-12
corrugated,
4 VCSG-23B 23 21 22.0 2805 50 12-17
Colored black,
5 VCSG-29B Halogen free, UV 29 29 27.7 34.4 60 17-21
resistant
6 VCSG-36B 36 36 35.8 42.4 70 21-28
7 VCSG-48B 48 48 46.8 54.4 80 28-38
Page: 1B-01-01-00-22

The design and performance data of the flexible conduits is as follows:
(a) Material: VCS Polyamide 6 specially modified for cold impact.
(b) Color: Black.
(c) Type: Heavy-wall.
(d) Flame properties: Self-extinguishing, free of halogen, phosphor and cadmium.
(e) Mechanical properties: Highly flexible.
(f) Temperature range: -50°C to 105°C. Short-term to 150°C.
(g) Chemical resistance: To fuels, mineral oils, fats, alkalies, acids and bases, etc.
(h) Excellent mechanical properties also at low temperatures.
Page: 1B-01-01-00-23
7 Terminals
The range of cables and stud bolts installed on the train determines the size of the
copper terminal lugs. The round type of terminal lug with 1-hole is used in this train.
Fig. 1B-01-01-00-15 Terminal Lug
Fig. 1B-01-01-00-16 Layout of Terminal Lug

Page: 1B-01-01-00-24
Table 1B-01-01-00-13 Specifications of Terminal Lugs
BOLT
M5 M6 M8 M10 M12
CABLE
Cable Part No.
(Max. Cross Vendor Part NO.
Sectional Area)
3GKW-6.0
PPEO0101-SR05 PPEO0101-SR06 PPEO0101-SR08 PPEO0101-SR10 PPEO0101-SR12
(3.25mm)
3GKW-16
(5.50mm)
3GKW-35
(8.05mm)
3GKW-50
(9.60mm)
3GKW -70
(11.75mm)
3GKW -95
(13.20mm)
4GKW -AX-35
(8.05mm)
4GKW -AX-70
(11.85mm)
4GKW -AX-95
(13.30mm)
4GKW-AX-150
(17.30mm)
4GKW-AX-185
(19.05mm)
4GKW-AX-J-
185(20.25mm)
Page: 1B-01-01-00-25

PART NUMBER SYSTEM
PPEO 0101 -X X 05
STUD SIZE
TONGUE FORM {R: ROUND TYPE, S: SQUARE TYPE}
BARREL FORM {S: 1-CLAMPING TYPE, L: 2 - CLAMPING TYPE}
WIRE TYPE
PRODUCT PART {PPEO: 1-HOLE TYPE, PPET: 2-HOLE TYPE}
8 Connectors
8.1 MS Connectors
MS connectors interface between equipment on the undercarriage of the train due to
the harsh environment encountered in this location and due to the presence of dust,
oil, fluids, etc.
Design considerations include:
(a) Wire sealing and terminal-to-terminal sealing.
(b) Corrosion resistance or proofing.
(c) Ability to connect/disconnect in extreme conditions.
(d) Multiple arrangements and docking.
(e) High quality while maintaining affordability.
The connector uses MS connectors use bayonet coupling mechanisms and crimp
type rear release contacts.
Connector receptacles include box mounting, single hole mounting configurations.
The connectors are designed to MIL-C-26482, series 2 type connector specifications.
Table 1B-01-01-00-14 List of MS Connector
No. Part. No. Description Contacts Quantity #AWG

1 MS3474W 14-5P RFI Connector Receptacle 5#16
2 MS3474W 24-31P RFI Connector Receptacle 31#16
3 MS3475W 14-5S RFI Connector Plug 5#16
4 MS3475W 24-31S RFI Connector Plug 31#16
Page: 1B-01-01-00-26
Fig. 1B-01-01-00-17 Layout of RFI Connector Receptacle
Table 1B-01-01-00-15 Specifications of RFI Connector Receptacles
C D
Part No. Size A Max. B Max. (-.005,+.001) E Thread F Thread
Max.
1-20 7/8-20
MS04CW-14-**P/S* 14 1.391 1.516 0.875 0.875
UNEF UNEF
1 3/8-18 1 3/8-18
MS04CW-20-**P/S* 20 1.828 1.954 1.250 1.178
UNEF UNEF
1 5/8-18 1 7/16-18
MS04CW-24-**P/S* 24 2.078 2.2032 1.500 1.437
UNEF UNEF
Fig. 1B-01-01-00-18 Layout of RFI Connector Plug

Page: 1B-01-01-00-27
Table 1B-01-01-00-16 Specifications of RFI Connector Plugs
Part No. Size A Max. B Thread C Min.

MS05CW-14-**P/S* 14 1.250 .875-20UNEF-2A 0.849
MS05CW-20-**P/S* 20 1.780 1.1875-18UNEF-2A 1.154
MS05CW-24-**P/S* 24 2.080 1.4375-18UNEF-2A 1.404
Fig. 1B-01-01-00-19 Insert Arrangements
NOTE
The cavity identification shown in Fig. 1B-01-01-00-19 is for the pins insert
face (socket opposite) and is for reference only.

Design and performance data for the MS connectors is as follows:
(a) Insulation resistance: 100 MΩ minimum at 25°C
(b) Dielectric withstanding voltage: 1500 Volt AC (rms)
(c) Temperature: -55°C to + 175°C
(d) Current Ratings:
(i) 7.5 amps: Size 20 contact
(ii) 13.0 amps: Size 16 contact
(iii) 25.0 amps: Size 12 contact
(iv) 100.0 amps: Size 04 contact
(e) Temperature cycling:
No cracking, chipping or leaking after 5 test cycles from -55°C to + 175°C
Page: 1B-01-01-00-28
(f) Durability:
No electrical or mechanical defects after 100 cycles of mating and disconnecting.
(g) Physical shock:
No unlocking, disconnecting or other unsatisfactory results after 100 G's in each
of three mutually perpendicular planes.
(h) Vibration:
Properly wired and mated connector assemblies will withstand 12 hours (4 hours in
each of three mutually perpendicular axes) of 20g peak sinusoidal vibration
between 10 and 2000 Hz without loss of electrical continuity in excess of one
microsecond.
(i) Contact retentions:
(i) 10 lbs. minimum: Size 20 contact
(ii) 15 lbs. minimum: Size 16 contact
(iii) 20 lbs. minimum: Size 12 contact
(iv) 30 lbs. minimum: Size 04 contact
(j) Recommended wire sizes are shown in Table 1B-01-01-00-17.
Table 1B-01-01-00-17 Contact and Wire Sizes
Contact Size Wire Size (AWG) Max./Min. (inches)

04 06 0.292/0.280
12 12.14 0.142/0.097
16 16, 18, 20 0.109/0.065
20 20, 22, 24 0.083/0.040
(k) Water Immersion:
Properly wired and mated connector assemblies will withstand immersion under 4
feet of water for 24 hours without loss of electrical qualities and without any
leakage
(l) Corrosion Resistance:
Properly wired and mated connector assemblies will show no evidence or
corrosion after exposure to 5% salt spray for 48 hours.
8.2 FCI Connector, 59 Pin

The FCI connector is a rectangular connector with a lever locking system. The main
features of this connector are:
(a) High pin-count: 59 contacts.
(b) Robust steel stamped shell.
(c) One-touch lever locking system for easy mating/unmating.
(d) Discrimination keying available to avoid mismatching connectors when racked.
Page: 1B-01-01-00-29
Fig. 1B-01-01-00-20 FCI Connector Plug, 59 Pin
Table 1B-01-01-00-18 FCI Connector Plug, 59 Pin Material
No. Part Name Material Remarks

1 Insulator Glass reinforced PBT resin Coloured black
2 Lever Stainless Steel
3 Hood Steel Nickel plated finish
4 Guide Pin Stainless Steel
5 Guide Socket Stainless Steel
6 Cable Clamp Bar Steel Nickel plated finish
7 Screw Steel M3 x 12
Page: 1B-01-01-00-30
Fig. 1B-01-01-00-21 FCI Connector Receptacle, 59 Pin
Table 1B-01-01-00-19 FCI Connector Receptacle, 59 Pin Material
No. Part Name Material Remarks

1 Insulator Glass reinforced PBT resin Coloured black
2 Skirt Steel Nickel plated finish
3 Guide Pin Stainless Steel
4 Guide Socket Stainless Steel
5 Lock Pin Stainless Steel Nickel plated finish
6 Bracket Steel

The electrical and mechanical characteristics of the 59 Pin FCI connectors are as follows:
(a) Rating voltage: AC 750 V, DC 1000 V
(b) Rating current: 7.5 A to 13 A
(c) Insulation resistance: 5000M min
NOTE
Further details, please refer to wiring diagram DWG No. ED03355 (5/6)
and ED03361 (1/2).
Page: 1B-01-01-00-31
8.3 FCI Connector, 24 Pin and 36 Pin

This connector is constructed from polyamide and is of the non-fixed rectangular type.
24 pin and 36 pin types are used in the train.
Fig. 1B-01-01-00-22 24 Pin Connector Plug and Receptacle
Fig. 1B-01-01-00-23 36 Pin Connector Plug and Receptacle

Page: 1B-01-01-00-32
Fig. 1B-01-01-00-24 FCI Non-Fixed Rectangle Type Connector Plug
Table 1B-01-01-00-20 Specifications of 24 Pin and 36 Pin Plugs
Quantity Quantity of Dimension (mm)

No. Part No. of Contact Discrimination
Cavities Cavities A B C D E (Ø) F (Ø) G H I
1 SMS24PDH1 24 15 47.6 41.8 90.4 23.7 7.1 12.4 20.4 65.1 57.2
2 SMS36PDH1 36 24 62.5 31.7 128.0 49.1 8.8 13.0 24.5 71.2 63.3
Page: 1B-01-01-00-33
Fig. 1B-01-01-00-25 FCI Non-Fixed Rectangle Type Connector Receptacle
Table 1B-01-01-00-21 Specifications of 24 Pin and 36 Pin Receptacles
Quantity Dimension (mm)

Quantity of
of
No. Part No. Discrimination
Contact A B C D E (Ø) F (Ø) G H I
Cavities
Cavities
1 SMS24PDH1 24 15 39.7 35.3 90.4 21.2 7.1 12.4 20.4 57.2
2 SMS36PDH1 36 24 54.6 25.1 128.0 46.6 8.8 13.0 24.5 63.3
Page: 1B-01-01-00-34

The design and performance data of the 24 Pin and 36 Pin FCI connectors is as follows:
(a) Operating temperature: -55°C ~ 105°C.
(b) Insulation resistance: 5000 M min.
(c) Test potential: 2000 V AC.
(d) Durability: 500 matings and unmatings.
(e) Material: Polyamide 6.6.
(f) Flammability rating: UL94-V2.
8.4 Harting Connector (42P, 72P)

This connector is mainly used for Electrical Distribution Board or MCB panel of
vehicle. Also, this connector is 42 pin or 72 pin, and rectangular type.
8.4.2 Equipment Layout
Fig. 1B-01-01-00-26 Harting Connector (Plug and Receptacle)

Page: 1B-01-01-00-35

The design performance data of the 42 Pin and 72 Pin Harting connector is as follows:
(a) Material: Die cast aluminium
(b) Surface: Power-coated RAL7034
(c) Lock element: Steel, Zinc plated/ Han-Easy Lock
(d) Temperature range: -40°C ~ +125°C
8.5 Terminal Block

Terminal block of this train is a cage clamp type that makes possible for a
directly secure connection without any risk of damage to the conductor. Also a
colour of grey and 3 conductors through terminal blocks was selected.
Fig. 1B-01-01-00-27 3-conductor Through Terminal Block (279-681)

Rated voltage: 800V
Rated surge voltage: 8Kv
Current: 18A
Terminal block dimension:
(a) 279-681 type (3hole)
(i) Width: 4mm
(ii) Length: 62.5mm
(iii) Height: 27mm
(b) 279-831 type (4hole)
(i) Width: 4mm
(ii) Length: 73mm
(iii) Height: 27mm
Page: 1B-01-01-00-36
9 Accessories
9.1 Cable Harness Connectors, EMC
The cable harness connectors for EMC protection are used as circular connectors on
the train and they have the following characteristics:
(a) Very minimal loss of inner cross section.
(b) Complete pre-assemble possibilities in cable harness systems.
(c) High shielding value and low coupling resistance.
(d) Quick and easy assembly.
B = Black
VIM = Female Thread EMC
V = Seal Rings, Long Thread
G = Seal Rings
U = Thread
24 = Thread Size
7 = NW Conduit
G = Coarse Profile
T = Fine Profile
B VIM V-U 247 G
Fig. 1B-01-01-00-28 Cross section and dimension details of EMC Connector, Female
Page: 1B-01-01-00-37
Table 1B-01-01-00-22 Specifications of EMC Female Connectors
Specification
Index
Part No. Part Name Thread Nominal Dimensions (mm)
No. To
UNEF g D D L
7
1 BVIMV-U212-14 /8"-20 G 4 6.5 1.6 3
2 BVIMV-U247-14 1"-20 7G 14 31 15 83
EMC Connector 3
3 BVIMV-U293-14 Female Thread 1 /16"-18 23G 14 38 3.5 93
4 BVIMV-U323-14 UNEF (MILE-C- 5
1 /16"-18 23G 4 8 3.5 3
26482, II) 7
5 BVIMV-U359-14 1 /16"-18 9G 4 45 30 93
5
6 - 1 /8"-18 NW29 - - - -
1
7 BVIMV-U303-14 JAE 1 /4"-18 G 4 8 23.5 89
8 BVIMV-M353-F M-Thread M35 X 1.5 3G 3.5 0 23.5 -102
Fig. 1B-01-01-00-29 Cross section and dimension details of EMC Connector Male
Table 1B-01-01-00-23 Specifications of EMC Male Connectors
Specification
Index Nominal Dimensions (mm)
Part No. Part Name Fits to
No. PG
NW Ød
g ID L SW
Max.
1 BVEMV-P090T 9 10 11 27 9 65 25
2 BVEMV-P112T 11 12 11 30 11 68 28
3 BVEMV-P137G 13.5 17 11 34 15 72 32
4 BVEMV-P167G EMC Connector 16 17 11 34 15 72 32
5 BVEMV-P213G Male Thread PG 21 23 12 43 23 85 41
6 BVEMV-P299G 29 29 12 49 30 85 46
7 BVEMV-P366G 36 36 13 58 38 94 55
8 BVEMV-P488G 48 48 15 74 49 100 70
Page: 1B-01-01-00-38
Specification
Index Fits Nominal Dimensions (mm)
Part No. Part Name Thread
No. to
M Ød
NW g ID L SW
Max.
9 BVEMV-M162-10 M16x1.5 12 10 30 11.5 75 28
EMC Connector
10 BVEMV-M207-10 M20x1.5 17 10 35 15.0 84 32
Male Thread M
11 BVEMV-M253-11 M25x1.5 23 11 43 19.5 90 41

The design and performance data of the EMC connectors is as follows:
(a) Temperature range: -40°C to + 105°C.
(b) Short-term: 1600 C.
(c) Density: S = with NFN3 and "O" ring IP67 stat./IP65 dyn.
(d) Supplier: PMAFLEX.
9.2 Lock Nuts

Fig. 1B-01-01-00-30 Lock Nut
Fig. 1B-01-01-00-31 Layout of Lock Nut

Page: 1B-01-01-00-39
Table 1B-01-01-00-24 Specifications of Lock Nuts
Item Vendor's Dimension (mm)

Thread PG Material
No. No S e h
1 GMM-09 09 22 24.2 5.0
2 GMM-11 11 24 25.9 5.0
3 GMM-13 13.5 27 28.9 6.0
4 GMM-16 16 30 32.6 6.0
Nickel-Plated
5 GMM-21 21 36 38.8 7.0
6 GMM-29 29 46 50.2 7.0
7 GMM-36 36 60 66.5 8.0
8 GMM-48 48 70 78.0 8.0
9 BMN-09 09 22 24.2 5.0
9 BMN-16 16 30 32.6 6.0
Polyamide
10 BMN-21 21 36 38.8 7.0
11 BMN-36 36 60 66.5 8.0

The design and performance data of the lock nuts is as follows:
(a) Temperature Range: -40°C ~ +105°C
(b) Short-term: 150°C
(c) Vendor No.
Ex-1) GMM - 07
07 = PG Thread
GMM = Type (Brass Nickel-Plated)
Ex-2) B MN - 07
07 = PG Thread
MN = Type Polyamide
B = Black Colour
G = Green Colour
Page: 1B-01-01-00-40
9.3 Cable Glands

Fig. 1B-01-01-00-32 Cable Gland
Fig. 1B-01-01-00-33 Layout of Cable Gland
Table 1B-01-01-00-25 Specifications of Cable Glands
Length Of Spanner Weight

Item Vendor's Thread Fits To Cable-
Thread Under Width Kg/100
No. No Pg Ø From-To (A)
Part (B) (SW) pcsl
1 BSTP-16 16 10-14 10 27 1.3
2 BSTP-21 21 13-18 11 33 2.1
3 BSTP-36 36 22-32 13 53 7.7
Page: 1B-01-01-00-41

The design and performance data of the cable glands is as follows:
(a) Temperature Range: -30±C ~ +90±C
(b) Short-term: 150±C
(c) Material: Polyamide
(d) Protection: IP68
(e) Vendor No.
Ex-1) B ST P– 36 SL
SL = Lock–Nut
36 = Thread Size
P = PG Thread
ST = Type Polyamide
B = Black
S = Grey

BMT1B 01 01 00 A1

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Volume I: Technical Manual BMRCL - Rolling Stock

Part B: Technical Descriptions of Equipment Systems Revision No: A0

BMRCL Rolling Stock

Volume I: Technical Manual

Section 1.1 Cabling

THIS PAGE INTENTIONALLY LEFT BLANK

Section 1B-01-01-00: Cabling........................................................... 1B-01-01-00-01

3 Low Tension Cables................................................................... 1B-01-01-00-05

4 Signal Cables .............................................................................. 1B-01-01-00-07

5 Cable Duct................................................................................... 1B-01-01-00-16

6 Flexible Conduits........................................................................ 1B-01-01-00-19

9 Accessories ................................................................................ 1B-01-01-00-35

Sub-section 1B-01-02-00: Overall .................................................... 1B-01-02-00-01

2 Specification of Components .................................................... 1B-01-03-00-06

Section 1B-01-04-00: Relay Panel .................................................... 1B-01-04-00-01

Section 1B-01-05-00: Electrical Distribution Board........................ 1B-01-05-00-01

Section 1B-01-06-00: MCB Panel 1 .................................................. 1B-01-06-00-01

Section 1B-01-07-00: MCB Panel 2 .................................................. 1B-01-07-00-01

Section 1B-01-08-00: DC-DC Converter........................................... 1B-01-08-00-01

Section 1B-01-01-00: Cabling

2 High Tension Cable

Table 1B-01-01-00-01 List of High Tension Cables

⑧ Conductor size (mm2)

Fig. 1B-01-01-00-01 750V DC System

2.2 Cross section of cable

1 Conductor, standed tin coated copper (IEC 228 Class 5).

Fig. 1B-01-01-00-02 Layout of High Tension Cable

2.3 Design and Performance Data

No Wire & Cable Name Part No. Remarks

Table 1B-01-01-00-02 Specifications of High Tension Cables

Cable Conductor Wall Cable-D R20 CH20** Weight

2.3.2 High Tension Power Cable, Flexible

No Wire & Cable Name Part No. Remarks

Table 1B-01-01-00-03 Specifications of High Tension Cables, Flexible

3 Low Tension Cables

Table 1B-01-01-00-04 List of Low Tension Cables

3.2 Equipment Layouts

1 Conductor, flexible tin-plated copper.

Fig. 1B-01-01-00-03 Layout of Low Tension Cable

3.3 Design and Performance Data

Table 1B-01-01-00-05 Specifications of Low Tension Cables

* (Typical value x single wire diameter)

4.1.2 Equipment Layouts

1 Conductor, flexible tin-plated copper.

Fig. 1B-01-01-00-04 Layout of 1-Core Unshielded Cable

1 Conductor, flexible tin-plated copper, coloured grey

Fig. 1B-01-01-00-05 Layout of Multi-Core Unshielded Cable

4.1.3 Design and Performance Data

* (Typical value x single wire diameter)

4.2 Shielded Cables

⑧ Conductor size (mm2)

4.2.2 Equipment Layouts

1 Conductor, flexible tin plated copper, colour : white

Fig. 1B-01-01-00-06 Layout of Multi-Core Shielded Cable

4.2.3 Design and Performance Data

4.3 Fire Resistant Cables

No Wire & Cable Name Part No. Remarks

4.3.2 Equipment Layouts

1 Conductor, tin-plated copper, Colour : grey, black numbered

Fig. 1B-01-01-00-07 Layout of Fire Resistant Cable

4.3.3 Design and Performance Data

Fig. 1B-01-01-00-08 Specifications of Fire Resistant Cables