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Product

UIC 541-5 9-pole ep-brake & NBÜ rail jumperUIC 541-5 (9-Pole)EN 45545-2 HL3ep-Brake + NBÜ + TB 0

UIC 541-5 Jumper Assembly9-pole UIC 541-5 electropneumatic brake (ep), NBÜ & TB 0 door-control inter-coach jumper

Inter-vehicle 9-pole railway jumper assembly built to UIC 541-5, EN 50264 and EN 45545-2 HL3 for electropneumatic brake actuation (ep-brake), passenger alarm override (NBÜ) and door control (TB 0) between coaches.

Flame-retardant
Anti-torsion braid
Ozone, UV & moisture
Approved
Order designation
UIC541-5-PP-9P-1500
Assembly length
1,500 mm
Cable OD
17.5 mm
Assembly weight
2.68 kg
Fire hazard class
HL3 (R15/R16)
All sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Standard
UIC 541-5
9-pole ep-Brake, NBÜ & TB 0 door control
Core layout
5×2.5 + 2×2×1.5
5 control cores + 2 screened pairs
Contact rating
110 V / 25 A
Pins 1–5 (2.5 mm²) · Pins 6–9 (1.5 mm²)
Fire safety
EN 45545-2 HL3
R15/R16 LSZH cross-linked EM 104
Shock / Vib
IEC 61373 Cat 2
Bogie/car-body inter-coach flexing
Sealing
IP66 / IP67
Latching hinged cap & trumpet gland

Typical values for this cable type, based on UIC 541-5 / EN 50264-3-1 / EN 45545-2 HL3 / IEC 61373 — confirmed in the datasheet and quotation for your order.

Application fit

Is UIC 541-5 Jumper Assembly right for your machine?

Engineered for continuous inter-coach hanging loop flexing, aerodynamic ballast stone impact, and −40 °C ice buildup on main-line passenger coaches.

Free-hanging vertical run

Suitable

Bell-mouth bend-relief boots and Class 5/6 tinned copper conductors withstand millions of inter-coach pitch, yaw and roll cycles.

TBM gantry & advancing tunnel reel

Suitable

Electron-beam cross-linked LSZH elastomer (EN 50264 EM 104) meets EN 45545-2 Hazard Level HL3 (R15/R16).

Fixed installation

Suitable

Resistant to ozone, UV, diesel fuel, brake dust, de-icing salts and −40 °C sub-zero temperatures.

Energy chain / drag chain

Not suitable

Inter-coach hanging jumper is designed for railway vehicle couplers, not machine-tool drag chains.

Use M23 Servo Assembly
Typical machinesMain-Line InterCity Passenger CoachesLocomotive Push-Pull & Multiple-Unit SetsInternational Cross-Border Night TrainsRolling Stock Overhaul & ModernizationUIC ep-Brake & NBÜ Safety Retrofits

Construction

Layer by layer

Standard UIC 541-5 9-core cable construction: 5 × 2.5 mm² (ep-brake apply, release, holding, return & door control) + 2 × (2 × 1.5 mm²) individually screened twisted pairs (NBÜ emergency brake override & intercom/monitoring) + overall tinned copper screen + EN 50264 EM 104 LSZH outer sheath.

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Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Fine-stranded tinned copper conductors5 × 2.5 mm² + 4 × 1.5 mm² (arranged as 2 × 2 × 1.5 mm² pairs) tinned copper to EN 60228 Class 5 / Class 6Carries 24–110 V DC ep-brake solenoid currents and low-loss NBÜ pilot signals along 400 m train consists
2Cross-linked halogen-free EI 109 insulationElectron-beam cross-linked polyolefin elastomer (EN 50264-1 EI 109) with permanent core numberingMaintains dielectric integrity from −40 °C to +90 °C導体 temperature
3Individual pair & overall tinned copper braidTinned copper braided screens (≥ 85 % optical coverage) over each 2 × 1.5 mm² pair and over the complete 9-core bundlePrevents 15 kV / 16.7 Hz and 25 kV / 50 Hz catenary traction return currents from inducing false brake or door signals
4Halogen-free separating & torsion-slip tapeNon-hygroscopic fleece wrap under the outer sheathAllows internal cores to slide freely during 3-axis inter-coach curve articulation
5Heavy-duty cross-linked LSZH elastomer (EM 104)Thick-wall black electron-beam cross-linked LSZH elastomer outer sheath to EN 50264-1 EM 104 / EN 45545-2 HL3Resists flying ballast stones, oxalic acid car-wash chemicals, mineral oil and tunnel fire smoke toxicity

UIC541-5-PP (Plug-to-Plug Removable Jumper)

Double-ended 9-pole UIC 541-5 male plug to 9-pole male plug jumper for twin-receptacle coach headstocks

UIC541-5-PJ (Fixed Junction-Box Pigtail Jumper)

Single 9-pole UIC 541-5 plug on one end and M32/M40 EMC cable gland + crimped ring terminals on the coach junction-box end

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on UIC 541-5 / EN 50264-3-1 / EN 45545-2 HL3 / IEC 61373. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated operating voltage
110 V DC / 250 V AC (cable 0.6/1 kV to EN 50264)
Contact current (Pins 1–5)
25 A max (2.5 mm² ep-brake & door control)
Contact current (Pins 6–9)
16 A max (1.5 mm² screened NBÜ / pilot pairs)
Contact resistance
≤ 1.5 mΩ (silver-plated machined brass contacts)
AC dielectric test
2.0 kV AC rms for 1 min (connector) · 3.5 kV AC (cable)

Thermal

Ambient operating range
−40 °C to +85 °C
Max. conductor temperature
+90 °C continuous · +200 °C short-circuit

Mechanical

Core configuration
5 × 2.5 mm² + 2 × (2 × 1.5 mm²C) C (OD ≈ 17.5 mm)
Vibration & shock
IEC 61373 Category 2 (bogie / headstock mounted)
Mating cycles
≥ 1,500 coupling cycles
Breakaway safety
Controlled pull-out disconnection under unscheduled uncoupling
Min. bend radius
6 × OD dynamic inter-coach loop

Resistance

Fire & smoke safety
EN 45545-2 HL1 / HL2 / HL3 (R15 indoor / R16 outdoor)
Halogen & smoke density
EN 60754-1/2 zero halogen · EN 61034-2 ≥ 70 % transmittance
Ingress protection
IP66 / IP67 mated or parked in dummy receptacle
Fluid resistance
EN 50264 mineral oil, diesel, acid & alkaline car-wash

Reference standards

UIC interoperability
UIC Leaflet 541-5 (9-pole ep-brake & door control)
Railway cable standard
EN 50264-3-1 / EN 50264-1 (EI 109 / EM 104)
Shock & vibration
EN 61373 / IEC 61373

Identification

Outer sheath colour
Black with white UIC 541-5 & EN 45545-2 HL3 legend
Pin polarization
UIC 541-5 non-interchangeable mechanical keyway
Customs tariff (HS)
8544.42 / 8607.99

Sizes

12 standard UIC 541-5 9-pole railway inter-coach jumper assemblies

Plug-to-plug (PP) and plug-to-junction-box (PJ) assemblies in standard coach headstock loop lengths.

Assembly style, length, pinout & weight
Order designationTermination ConfigurationCable Core BuildLength
mm		Cable OD
mm		Assy Wt
kg		Fire Class
EN 45545-2		Enquiry
Plug-to-Plug (PP) Double-Ended UIC 541-5 Jumper Assemblies
UIC541-5-PP-9P-12009P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C1,20017.52.45HL3 (R15/R16)
UIC541-5-PP-9P-14009P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C1,40017.52.60HL3 (R15/R16)
UIC541-5-PP-9P-15009P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C1,50017.52.68HL3 (R15/R16)
UIC541-5-PP-9P-16509P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C1,65017.52.80HL3 (R15/R16)
UIC541-5-PP-9P-18009P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C1,80017.52.92HL3 (R15/R16)
UIC541-5-PP-9P-20009P Plug ↔ 9P Plug (Metal Housing)5×2.5 + 2×(2×1.5C)C2,00017.53.08HL3 (R15/R16)
Plug-to-Junction-Box (PJ) Fixed Pigtail & Receptacle Kits
UIC541-5-PJ-9P-13509P Plug → M32 EMC Gland + Lugs5×2.5 + 2×(2×1.5C)C1,35017.52.10HL3 (R15/R16)
UIC541-5-PJ-9P-15009P Plug → M32 EMC Gland + Lugs5×2.5 + 2×(2×1.5C)C1,50017.52.22HL3 (R15/R16)
UIC541-5-PJ-9P-17009P Plug → M32 EMC Gland + Lugs5×2.5 + 2×(2×1.5C)C1,70017.52.38HL3 (R15/R16)
UIC541-5-PJ-9P-20009P Plug → M32 EMC Gland + Lugs5×2.5 + 2×(2×1.5C)C2,00017.52.62HL3 (R15/R16)
UIC541-5-PJ-9P-25009P Plug → M32 EMC Gland + Lugs5×2.5 + 2×(2×1.5C)C2,50017.53.02HL3 (R15/R16)
UIC541-5-REC-1500-KIT9P Coach Receptacle + 1.5 m Tail5×2.5 + 2×(2×1.5C)C1,50017.52.85HL3 (R15/R16)
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • UIC 541-5 standard pin functional allocation: Pin 1 = Apply ep-brake (+), Pin 2 = Release ep-brake (+), Pin 3 = Holding check, Pin 4 = Common return (−), Pin 5 = Door control (TB 0), Pins 6–9 = Screened pairs for NBÜ emergency brake override.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
100 % 2.0 kV AC hipot, insulation resistance & pin-to-pin continuity testVerify UIC 541-5 wiring diagram, pair shield isolation and ≤ 1.5 mΩ contact resistanceEvery jumper assembly
Sample tests
Pull-out retention & trumpet bend-relief flex testVerify controlled breakaway force and 100,000-cycle inter-coach oscillation testQualification lot
EN 45545-2 HL3 fire, smoke density & toxicity verificationEN 60332-1-2, EN 60332-3-24, EN 61034-2 & EN 60754-2Cable type approval

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

UIC Leaflet 541-5 9-Pole Interoperability CompliantEN 45545-2 HL3 & EN 50264-3-1 Rolling Stock Certified

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX UIC 541-5 EP-BRAKE JUMPER EN 50264 EM104 EN 45545-2 HL3
Packaging
Individually boxed with serialized routine test protocol & EN 45545-2 DoC
Accessories
Matching coach-end UIC 541-5 flanged sockets & parking dummy receptacles
Custom options
Stainless-steel anti-ballast protection hose or custom gland threads
Lead time
3–5 weeks ex-works

Technical documents

Downloads

PDFUIC 541-5 Jumper Assembly – technical datasheet12 sizes · construction, technical data, approvalsXLSXUIC 541-5 Jumper Assembly spec data (Excel)All 12 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

What functions are carried by the 9 poles of a UIC 541-5 inter-coach jumper?
Pins 1 to 5 (2.5 mm²) carry the electropneumatic brake (ep-brake) apply, release, holding feedback, return, and TB 0 lateral door-closing control signals. Pins 6 to 9 (two individually screened 1.5 mm² twisted pairs) carry the NBÜ (Notbremsüberbrückung) passenger emergency-brake override loop so a train does not halt inside a tunnel.
Can a UIC 541-5 plug accidentally be inserted into a UIC 558 (18-pole) or UIC 552 (HV) receptacle?
No. UIC 541-5 uses a distinct 9-pole contact insert and mechanical housing keyway that is physically non-interchangeable with 18-pole UIC 558 remote-control sockets or high-voltage UIC 552 train-line sockets.
Why are pins 6–7 and 8–9 constructed as individually braided twisted pairs?
The NBÜ emergency brake override and diagnostic loops run the entire length of the train parallel to the 1,000 V / 1,500 V / 3,000 V UIC 552 power line and catenary return rails. Individual ≥ 85 % tinned-copper braids prevent 16.7 Hz or 50 Hz traction harmonics from inducing false signals.
What happens if two coaches uncouple while the UIC 541-5 jumper is still plugged in?
The UIC 541-5 plug latch and receptacle spring cover are engineered as a controlled breakaway mechanism: when axial tension exceeds the coupling limit, the spring cover lifts and releases the plug cleanly before the cable or coach headstock is torn off.

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