High Performance Wire and Cable

distributed by Northwest Rail Electric

Phone: (503) 231-4808, Fax: (503) 230-0572, E-mail

Here is a description of the high performance electric wire and cable we distribute for the railroad industry. This wire is also used in the transit industry (particularly in subway applications), as well as other industrial uses that require electrical wire that can survive in demanding environments.

The following information was supplied by General Cable. Polyrad XT is a registered trademark of General Cable. Other manufacturers of railway approved wire exist, and the specific details of their process, and specific approvals, will be somewhat different. This information should therefore only be taken to be an example of what is available.

GENERAL CABLE BRAND REX POLYRAD XT LOCOMOTIVE/TRANSIT WIRE AND CABLE

Product Description

General Cable Brand-Rex Polyrad XT is a unique insulation system which utilizes thermosetting polyolefin compound crosslinked by radiation. This process produces maximum flame retardance, oil and chemical resistance, low smoke properties and outstanding mechanical toughness. Polyrad XT's excellent overall balance of properties is generally not attainable with conventional insulating systems. Polyrad XT single conductor locomotive and rapid transit car cables are rated either 110 Deg. C or 125 Deg. C and supplied in both 600 volt and 2000 volt constructions.

Multiple conductor constructions are available.

(NOTE: Northwest Rail Electric DOES NOT STOCK 2000 volt insulation wire, or most types of multiple conductor forms.)

Product Features and Benefits

General Cable Brand Rex Polyrad XT wire and cables combine superior properties and performance for locomotive, rapid transit and offroad equipment applications.

Excellent flexibility and free stripping
Higher ampacities and simplified installations possible due to small outside diameters, flexible stranding and insulation
Outstanding thermal stability at elevated temperatures
Maximum flame-retardance and low toxicity
Excellent low temperature performance; suitable for installation in sub-zero conditions Meets cold bend test at -55 deg C and meets cold impact test at -40 deg. C
Extra tough, mechanically rugged irradiated thermoset insulation
Resistant to most oils and chemicals
110 Deg. C temperature rating for long life, higher ampacities and protection from thermal overloads (single wires).
125 Deg. C maximum conductor temperature, locomotive cable.
Maximum dependability and mechanical toughness
High ampacities and simplified installations made possible by small outside diameters, and flexible stranding.

Applications

Ideally suited for use where environmental factors require cable characteristics to perform with a high degree of flame-retardancy and excellent moisture-stable electrical values, where reliability is the major concern and where maximum performance will be demanded.

Engineered and manufactured for both original equipment and retrofit use in power and control circuits, and in motor leads.

Extensively found on all types of heavy- and light- rail cars, rapid transit cars, diesel electric locomotives, wayside equipment and off-road vehicles.

Insulation System and Construction

General Cable Brand-Rex Polyrad XT insulation features a highly engineered and refined polyolefin formulation used in conjunction with soft annealed, tinned copper conductors per ASTM B-33. This insulation system combines outstanding flame retardancy with excellent moisture-stable electrical values. The construction is further enhanced by radiation crosslinking which transforms the original thermoplastic into a rugged thermosetting material. The result is a compound with excellent thermal stability - it will not soften or flow at elevated temperatures. Polyrad XT also has increased toughness, greater resistance to cut-through, superior oil resistance and improved low temperature performance.

The Radiation Process

In radiation crosslinking, a scanner directs a high energy electron beam from a power source accurately and uniformly over the wire insulation. General Cable has perfected this technique enabling us to effectively process small wires with thin insulation walls. The same technology is also used to measure the precise degree and uniformity of crosslinking.

Approvals

General Cable Brand Rex Polyrad XT cables are manufactured, tested and inspected in accordance with the latest issue of the following standards:

AAR S-501 and AAR RP-585: Wiring and Cable Specification
ICEA S-95-658: Nonshielded 0-2 kV Cables
IEEE 1202: Flame Test at 70,000 BTU/hour
IEEE 383: Flame Test at 70,000 BTU/hour
UL VW-1: Flame Test
BSS 7239: Toxic Fumes
SMP 800-C: Toxic Gas Generation
ASTM E662: Standard Test Method for Specific Optical Density of Smoke Generated by Solid Materials
49 CFR Part 238: Flame and Smoke Requirements

Sizes Available

General Cable Brand-Rex Polyrad XT is available with the following insulation ratings:

600 Volt, 110 Degree C.
600 Volt, 125 Degree C.
2000 Volt, 110 Degree C.
2000 Volt, 125 Degree C.

The table below lists the sizes available as well as the rated current capacity in relation to the size and insulation temperature rating of the wire.

Items in Italics are not available as a standard product, but are available as a custom order. Minimum quantities may be required.

Northwest Rail Electric DOES NOT STOCK 2000 volt wire. We can obtain this voltage insulation on special order, but the order will take some time for processing.


  APPROX     APPROX            CABLE AMPACITY
   AREA       AWG             SINGLE CONDUCTOR
  (CMIL)      SIZE        FREE AIR 40 DEG C AMBIENT
                         110 DEG C       125 DEG C
--------------------------------------------------
      *      20*            24*            26*
  1900*      18*            30*            32*
  2601       16             35             38
  3831       14             41             44
  6088       12             52             56
  10910      10             73             79
  14950      8              85             92
  24640      6              120            130
  36760*     5*             160*           173*
  42420      4              168            181
  50500*     3*             199*           215*
  60600      2              214            231
  90900      1              268            289
  111100     1/0            304            328
  131300     2/0            338            364
  181800     3/0*           414*           446*
  222200     4/0            472            509
  262600*                   524*           565*
  313100*                   590*           636*
  373700*                   657*           708*
  444400*                   734*           791*
  535300*                   828*           893*
  646400*                   931*           1004*
  777700*                   1047*          1129*
  929200*                   1168*          1259*
 1111000*                   1254*          1352*

* This size is available only by special order. It is not stocked by Northwest Rail Electric.

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