APPLICATIONS

RAILWAY INDUSTRY
 INNOVATIVE TECHNOLOGY FROM WEIDMÜLLER

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A QUALITY PORTFOLIO FOR TRAINS AND TRACKS

Running a modern and high-performance transport system is a great logistical challenge and
demands fast, flexible, efficient and safe railway vehicles which requires short periods of immobi-
lisation and servicing. These demands are reflected by technical concepts with innovative elec-
trical connection technology.

Terminals, connectors, enclosures or marking systems – Weidmüller has been developing and
fine-tuning components in order to fulfil the special requirements of the rail industry for 50 years.
Our products are put to the test in railway day in, day out, proving their resilience to vibrations,
impacts and climatic conditions.

Weidmüller branches have been IRIS-certified, the new quality standard for the rolling stock indus-
try: with above-average results.

MAKING SURE TRAINS ARRIVE SAFELY AND ON TIME

Weidmüller is the leading provider of solutions for the electrical connectivity, transmission and
conditioning and processing of power, signals and data in industrial environments. With a standard
portfolio containing 35,000 products, and production plants and sales companies in more than 70
countries, Weidmüller is not only represented around the world; it is also your first port of call for
innovative solutions when it comes to industrial connection technology. We are your one-stop shop
for all applications!

As a member of the VDB (German Rail Industry Association) and the ZVEI rail team (Central
Association of the Electrotechnology and Electronics Industry), we are familiar with the demands
placed on modern transport systems. As a partner of the rail industry, we have been consistently
delivering top-quality goods and a range tailored to suit rail use for years. These credentials
played no small part in the German rail company Deutsche Bahn AG’s move to rate us as a L1
supplier – acknowledging our production engineering standards and quality, as well as com-
mercial aspects.

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 MODULARITY AND PLATFORM DESIGN
Brake
control
As the need for mobility grows, so do the demands placed on the various interior and exterior system
applications and components on railway. Increasingly individualised, higher-performance inter-
Driver’s
faces are particularly sought-after for the development of innovative platform concepts for cabin

different train types.

Weidmüller supports these innovative platform concepts with a whole range of solutions and
a broad product portfolio.

SAFE AND MODULAR

• Wiring for prefabricated

functional units
• Conductor cross-section • Easy, faultless, pluggable
0.08–35 mm 2 connection
• Integrated test point • Spring-powered pluggable
• Clear top-entry connection contact
• Pluggable cross-connections • Efficient, modular, flexible
• Mini terminals, 3.5 mm wide • 500 V, 24 A

Z series WeiCoS
Tension clamp terminals Pluggable terminals

• Installation inside and out-

side of rolling stock
• Robust Ethernet cables
designed specifically for
railway applications
• Extruded cables also
available in customer- • Corrosion-resistant
specific models IP67 stainless steel housing
• Connectors with tension • Wide range
clamp • Protection class IP66 to IP68

M12 D-coded Klippon® TB range

Ethernet connector Enclosures

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 Air condition system

Traction motor connection

Door control
Light
Wagon-to-wagon connection

Battery charger

Auxiliary converter

Inverter container

Control cabinet

• Efficient power distribution • Efficient power distribution on

up to 4 kV mounting rails up to 120 mm 2
• Low voltage drop • Low voltage drop
• Self-extinguishing material, • Self-extinguishing material,
classified V0 according to classified V0 according to UL 94
UL 94 • 1,000 V (with epoxy resin
• Approved according to interna- partition up to 2,300 V)
tional railway standards such • Approved according to interna-
as EN 50343, EN 50155, tional railway standards such as
NF F 61-017, NF F 16-101 EN 50343, EN 50155, NF F 61-017,
and Ria 20 NF F 16-101 and Ria 20

ST 4000 WF series
Stud terminals Stud terminals

• Weight-optimised HDC • High power in a small space

housing • Up to 46 pins
• EMC-protected • 500 V, 16 A
• Hardened surface • Impact and vibration-tested accor-
• Protection class IP68 ding to IEC 61373, category II

RockStar® HEE
Heavy-duty connector Inserts

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 WEIDMÜLLER AND THE RAILWAY INDUSTRY

High-speed trains, trams, metros or locomotives – they all run safely with electrical connection
technology from Weidmüller. We have been cooperating with leading rail manufacturers around
the world for years, in order to fulfil the demand for mobility by offering innovative, customer-
specific solutions.
Our aim is to increase your competitiveness via simple, optimised connections and interfaces.

OPTIMUM SOLUTIONS

• 6 mm slim relay coupler

• Safe and quick tension clamp
connection
• Self-extinguishing, insulating
Wemid material, classified V0 • Safe shield connection
according to UL 94 • Easy to use
• Fulfils requirements according • Quick assembly – no need
to EN 50155 for tools

MCZR TRAK KLBU 4-13

Relay coupler Shield connection

• Shrinkable sleeves that can

be printed on both sides, for • Ergonomic operation
cable marking • Self-adjustable stripping
• Halogen-free blades
• Complies with international • Integrated cutting function
traffic engineering standards • Long durability

TwinMark stripax®
Shrinkable sleeves Stripping tool

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CUSTOMER-SPECIFIC SERVICES

We have been offering our customers tailored services for over 35 years, with a focus on individ-
ually adapted enclosures and assembled mounting rails. And that means maximum flexibility and
cost-effectiveness for you!

• Expert project consultancy

• Professional assembling, drilling, milling, coating,
engraving and labelling
• More flexibility for your production

Customer-specific enclosures

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 SOLUTIONS FROM WEIDMÜLLER

During the railway’s life cycle, maintenance costs considerably outstrip acquisition costs. The time
needed for servicing can be cut dramatically by using connections that are quickly disconnected,
meaning that Weidmüller makes a significant contribution towards cutting life cycle costs (LCC).

We therefore fulfil our customers’ demands for durability and cost-effectiveness – in all
applications!

APPLICATIONS
Fotos: DB AG (S. 1, 2, 6, 7, 8)

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 APPLICATION: WAGON-TO-WAGON CONNECTION

Robust products are essential in tough condi-

tions, but they must also provide a cost-effective
solution. Our stud terminals and heavy-duty
plug-in connectors do just that: they are easily
RockStar ® ST 4000 pluggable and easy to disconnect, making them
perfect for quickly coupling wagons. The heavy-
®
duty connectors with RockStar housing guaran-

WF series tee fast signal transmission, e.g. of the WTB

(wire train bus). Power is transmitted via
ST 4000 stud terminals and the WF series.

• Reliable, high power transmission

• 4 kV, 415 A
• Vibration-tested according to IEC 61373, category II

ST 4000
Stud terminals

• Quick-pluggable connection
for control signals
• Power transmission with • Weight-optimised HDC housing
optimised space • EMC-protected
• Max. 2,300 V, 269 A • Hardened surface for extreme
• Vibration-tested according mechanical strain
to IEC 61373, category II • Protection class IP68

WF series RockStar®
Stud terminals Heavy-duty connector

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 APPLICATION: CONTROL CABINET

All the train’s control signals come together in one

control cabinet. This is connected externally by means
of heavy-duty plug-in connections. Our space-saving
Z series terminals, MCZR TRAK-type relay couplers and
diode holders maintain an electric connection and
ensure that the signals in the control cabinet are
analysed reliably.

• Fulfil various requirements

with just one plug-in • Conductor cross-section
connector 0.08–35 mm 2
• Patented modular system • Integrated test point
• Range of modules up to • Clear top-entry connection
optical fibres and bus • Pluggable cross-connections
modules • Mini terminals, 3.5 mm wide

HDC ConCept Z series

Inserts Tension clamp terminals

• 6 mm slim relay coupler

• Safe and quick tension
clamp connection
• Self-extinguishing, insu-
lating Wemid material, • Tried and tested tension
classified V0 according clamp connection
to UL 94 • Protects from inverse
• Fulfils requirements current up to 3 A
according to EN 50155 • Vibration-resistant

MCZR TRAK Diode holder

Relay coupler

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APPLICATION: SANDING SYSTEM

Signals control the opening of the sanding system slider via an electrical interface. The electrics
are enclosed in K range aluminium enclosure with corrosion-resistant coating in order to protect
them from extreme environmental conditions. Thanks to the use of ZDUB mini block terminals on
a mounting rail measuring just 15 mm, the whole application takes up so little space that it fits
next to the sand feeder.

• Expert project consultancy

• Professional drilling, milling,
coating, engraving and labelling
• More flexibility for your • Extremely light aluminium
production enclosures
• “100 in 1” – we make one • Chemical and weather-
hundred single articles to one resistant
article • Protection class IP66 and IP68

Customer-specific services K range

Enclosures

• Robust cable gland made

• Maximum power in minimum of nickel-plated brass
space • EMC cable gland
• Mounted on TS 15 rail • High protection class IP66
• Clear top-entry connection to IP69K

ZDUB Cable entries

Mini block terminals

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 APPLICATION: DOOR CONTROLS AND DRIVER’S CAB

Flexible modular terminal concepts are needed wherever complete functional units are prefabri-
cated or replaced. That is why terminals with WeiCoS-type plug-in connectors are used in the
driver’s cab and door controls. This combination makes it possible to connect prefabricated func-
tional units with the existing installation quickly and faultlessly. Simply insert the plug-in
connector into the terminal and you are done! A spring-powered contact and the locking elements
guarantee that the contact withstands impacts, vibration and jolts.

• Easy final assembling with pluggable terminals

• Modular design for prefabricated functional units
• Easy, faultless, pluggable connection

WeiCoS
Pluggable terminals

• For feeding in prefabricated cables

• Quick and easy assembly
• For standard HDC panel cut-outs
• Protection class IP54

Cabtite
Cable entries

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APPLICATION: TRACTION MOTOR CONNECTION

In modern high-speed trains, high currents are sup-

plied to the motors to enable the train to accelerate to
its top speed. Our ST 4000 stud terminals have been
specially developed to transfer such high currents for
railway. The ST 4000 stud terminals are protected from
external conditions such as splashes of water, dust and
stones by corrosion-resistant stainless steel enclosure
from our TB range.

• Supply drive power up to 4 kV, 415 A

• Vibration-tested according to IEC 61373, category II
• Self-extinguishing material, classified V0 according to UL 94
• Low emissions, classified I2 F0 according to NF F16 101

ST 4000
Stud terminals

• Robust stainless steel enclosures

• Lid with concealed hinges
• Fixing lugs
• Corrosion-resistant electropolished stainless steel
• Protection class IP66 to IP68

Klippon® TB range
Enclosures

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 SOLUTIONS FOR INTERLOCKING SYSTEMS

From the control centre to outdoor systems with turnouts and signals to the heart of the system,
the electrical interface, interlocking system technology requires a high degree of safety and relia-
bility, and has to be fast at the same time. Weidmüller’s components have what it takes to deal
with all the various tasks in the field, and fulfil all the required norms. Weidmüller’s enclosures,
isolating terminals, Industrial Ethernet and PCB components, overvoltage protection, relays and
tools all guarantee first-class quality. We work in conventionally operated relay fields as well as in
modern electronic systems in accordance with the ETCS (European Train Control System) standard.
We also collaborate in numerous application-based projects and co-develop them.

• Expert project consultancy

• Professional drilling, milling,
coating, engraving and
labelling
• Optimum open electrical • More flexibility for your
isolator testing in the field production
• Straightforward top connec- • “100 in 1” – we make one
tion (from above) hundred single articles to one
• Pluggable cross connection article

ZTR Customer-specific services

Isolating terminals

• Installation inside and out- • High leakage current of

side of rolling stock 12.5 kA per pole (10/350 µs)
• Robust Ethernet cables • Suitable for lightning pro-
designed specifically for tection levels III and IV
railway applications • Optical display; pluggable
• Extruded cables also charge eliminator rotates
available in customer- 180°
specific models IP67 • Extensive overvoltage pro-
• Connectors with tension tector portfolio for classes
clamp I to III

M12 D-coded PU Series

Ethernet connector Lightning and overvoltage protection

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 Interlocking system
• Multi-voltage optocoupler with
24–110 Vdc input and
5–137 Vdc/0.25 A output
• Interruption of power supply
class S2
• Fulfils requirements in accor-
dance with EN50155 for voltage
fluctuations, temperature and
condensation
MCZ O TRAK
Optocouplers
• Single-colour printing
• Integrated loader for up to
20 MultiCards
• Highly resistant to wiping
and scratching
• Display features all relevant
information
PrintJet PRO
Marking system
Control center Signal
Point heating
Points controllers
Axle counter
• Innovative connection systems for
energy, signals and data: from the
most compact I/O LED connector
module to the most powerful prin-
ting terminal for 1,000 V/150 A
• A variety of standardised solu-
tions for efficient all-purpose con-
ditioning. Can be individually con-
figured
PCB
PCB terminals and connectors
• Ergonomic operation
• Self-adjustable stripping
blades
• Integrated cutting function
• Long durability
stripax®
Stripping tool
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 APPLICATION: INTERLOCKING SYSTEMS

Commands from the control centre converge in the Interlocking systems and are transmitted as
dependent signals to the turnout and signal systems, which should then form a functioning route.
These procedures are often processed in double and triple cabinets. When it comes to complex,
electronic control processes, it is important that the data and signals be well protected with over-
voltage protection and transmitted reliably and quickly. Weidmüller provides isolating terminals,
overvoltage protection, IE-passive cables and multi-relays designed specifically for signal box
applications.

• 4-fold change-over contact

for 24 Vdc control signals
• Fully installed kit with relay,
base, LED and retaining clip
• Optimum open electrical • Fulfils requirements in
isolator testing in the field accordance with EN 50155
• Straightforward top connec- for voltage fluctuations,
tion (from above) temperature and EN 61373
• Pluggable cross connection AK 1 class B for vibrations

ZTR 2,5 RIDERSERIES

Isolating terminal Multi-relays

• Installation inside and out-

• Thin design of just 6 mm with side of rolling stock
tension clamp • Robust Ethernet cables
• Overvoltage protection for designed specifically for
signals in 5 V, 12 V, 24 V, 48 V railway applications
and 60 V, such as current loops • Extruded cables also
and integrated components available in customer-
• Snap-on PE rail contact specific models IP67
• Safe energy elimination up • Connectors with tension
to 10 kA clamp

MCZ OVP series M12 D-coded

Overvoltage protection eliminator for I&C Ethernet connector

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APPLICATION: POINTS CONTROLLERS

The points controllers need to work seamlessly from

the point where the signal arrives from the Interlocking
system and where the guide selects the direction,
despite external weather conditions and dirt. Our STB
enclosures and cable entries serve as ideal interfaces,
conform to the IP68 protection class and are EMC-
protected. We also use Z-compact terminals and wire
clamps with shield connections in the points controllers.

• Expert project consultancy

• Professional drilling, milling,
coating, engraving and
labelling
• More flexibility for your
production
• “100 in 1” – we make one • Safer shield connection
hundred single articles to one • Easy to use
article • Quick tool-less installation

Customer-specific services KLBU 4-13

Shield connection

• Full performance, compact

design • Robust cable gland in
• Space and weight-saving nickel-plated brass
• Flexible tension clamp with • EMV cable gland
improved vibration-resistance • High protection class IP66
• Straightforward top connection to IP69K

Z-Compact Cable entries

Tension clamp technology

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 TESTED AND CERTIFIED

UNCOMPROMISING QUALITY

The components used for transport technology are constantly exposed to extreme conditions.
That’s why our products are tested in our own accredited laboratory for particularly relevant
criteria such as resistance to vibration, impacts and extreme temperatures, as well as durability
and electromagnetic compatibility.

To make sure you always receive top quality from Weidmüller, each of our products is subject
to strict quality assurance and fulfils the following international railway norms and standards:

General: DIN EN 50155, DIN EN 50343, NF F 61-017

Behaviour in fire: NF F 16-101, BS 6853, ASTM E 162
Resistance to impacts and vibration: IEC 61373/Ria 20

Our railway industry CD-ROM contains everything you need to know about standards and
approvals, tests passed according to railway norms, references, material tests and lots of further
information.
You can order your free copy of the railway industry CD-ROM by e-mailing railway@weidmueller.com.

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FOR EXTREME CONDITIONS

Left: Testing for impact and vibration-resistance simulates different mechanical strains
in the vehicle or on the bogie.
Right: We use the needle flame test to investigate how the plastics used behave in fire.

FOR ABSOLUTE SAFETY

Left: Our products are exposed to different climates in modern climatic test chambers.
Right: One of the many stages of quality control: the EMC test.

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www.weidmueller.com

Argentina Indonesia Saudi Arabia Weidmüller is the leading provider of solutions for
Australia Iran Serbia electrical connectivity, transmission, conditioning and
Austria Ireland Singapore processing of power, signals and data in industrial
Azerbaijan Israel Slovakia environments. The company develops, produces and
Bahrain Italy Slovenia sells products in the field of electrical connectivity,
Belarus Japan South Africa functional electronics and communication electronics.
Belgium Jordan Spain Weidmüller’s product and service portfolio is dedicated
Bosnia and Kazakhstan Sweden to add value to the products and thereby the business of
Herzegovina Korea Switzerland our customers. The Weidmüller Group has a global focus
Brazil Kuwait Taiwan with its own manufacturing plants, sales companies and
Bulgaria Latvia Thailand representatives in over 70 countries.
Canada Lebanon Tunisia
Chile Lithuania Turkey
China Luxembourg Ukraine
Colombia Macedonia United Arab
Costa Rica Malaysia Emirates
Croatia Malta United States
Czech Mexico Uruguay
Denmark Moldova Uzbekistan
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Great Britain Philippines
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Hungary Qatar
Iceland Romania
India Russia

Bestellnummer: 4032248820795
1067270000/09/2008/SMMW