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Product

UIC 552 3 kV / 800 A HV HEP rail jumperUIC 552 (ZS / HEP)1,000–3,000 V / 800 AEN 45545-2 HL3

UIC 552 Jumper Assembly1,000–3,000 V AC/DC up to 800 A UIC 552 High-Voltage Train Line (ZS / HEP) jumper

Single-pole high-voltage railway Head-End Power (HEP / ZS) inter-coach jumper built to UIC 552, EN 50264-2-1 (3.6/6 kV) and EN 45545-2 HL3 for 1,000 V 16.7/50 Hz, 1,500 V AC/DC and 3,000 V DC hotel power buses up to 800 A.

Flame-retardant
Anti-torsion braid
Ozone, UV & moisture
Approved
Order designation
UIC552-PJ-1X185-1500
Max current
800 A
Length
1,500 mm
Cable OD
31.5 mm
Assembly weight
7.8 kg
All sizes (12)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Standard
UIC 552 (ZS)
European RIC multi-voltage HEP line
Voltage rating
1.0–3.0 kV AC/DC
1.8/3 kV or 3.6/6 kV EN 50264 cable
Current rating
Up to 800 A
95, 120, 150, 185 or 240 mm² Class 6
Safety lock
HV Interlock
Cannot uncouple under live HV load
Fire safety
EN 45545-2 HL3
Cross-linked LSZH EM 104 / silicone
Sealing
IP66 / IP67
Cast aluminium/composite HV housing

Typical values for this cable type, based on UIC 552 / EN 50264-2-1 / EN 45545-2 HL3 / IEC 61373 — confirmed in the datasheet and quotation for your order.

Application fit

Is UIC 552 Jumper Assembly right for your machine?

Delivers up to 1.2 MW of locomotive auxiliary transformer power along passenger coach consists for HVAC, galley kitchens, battery chargers, and 230 V passenger sockets.

Free-hanging vertical run

Suitable

Class 6 extra-fine tinned copper conductor (95–240 mm²) and heavy bell-mouth strain relief endure continuous inter-coach curve flexing.

TBM gantry & advancing tunnel reel

Suitable

Certified to EN 45545-2 HL3 (R15/R16) with EN 50264-2-1 1.8/3 kV or EN 50382-2 3.6/6 kV cross-linked elastomer insulation.

Quayside shore-to-ship HVSC connection

Suitable

Supports both inter-coach hanging loops and stationary railway depot pre-heating shore supply up to 800 A.

Energy chain / drag chain

Not suitable

Inter-coach high-voltage jumper is engineered for railway vehicle couplers, not industrial machine drag chains.

Use M23 Servo Assembly
Typical machinesRIC International Passenger CoachesLocomotive-Hauled Push-Pull ConsistsHigh-Speed & Night-Train Hotel Power (HEP)Multi-System Cross-Border Rolling StockRailway Depot Shore-Supply (Vorheizanlage) Cables

Construction

Layer by layer

Representative UIC 552 HV jumper cable: 1 × 185 mm² (or 150 mm² / 240 mm²) IEC 60228 Class 6 tinned copper + 3.6/6 kV cross-linked HEPR/silicone dual-layer insulation + optional concentric earth/pilot monitor screen + EN 50264 EM 104 HL3 outer jacket.

12345
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1Extra-flexible Class 6 tinned copper HV core1 × 95 mm², 120 mm², 150 mm², 185 mm² or 240 mm² extra-fine stranded tinned copper to EN 60228 Class 6Carries 400 A to 800 A continuous HEP current while remaining flexible in −40 °C winter service
2Semiconductive stress-smoothing tape/layerConductive elastomer layer over the multi-rope Class 6 conductorPrevents corona and partial discharge at 3,000 V AC/DC operating voltage
31.8/3 kV or 3.6/6 kV cross-linked HV dielectricThick-wall electron-beam cross-linked EPR/HEPR (EN 50264-2-1 EI 109) or silicone rubber (EN 50382-2 EI 111)Provides high dielectric margin and +90 °C / +120 °C thermal endurance under 800 A peak load
4Optional concentric earth / safety pilot braidTinned copper braided earth screen (e.g. 25–35 mm² equivalent) + optional 2 × 1.5 mm² safety interlock pilot coresTrips the locomotive HV main circuit breaker immediately if outer insulation is damaged or uncoupled
5Heavy-duty EN 45545-2 HL3 outer elastomer sheathAbrasion- and stone-impact-resistant black (or high-voltage orange-striped) cross-linked LSZH elastomer (EM 104)Protects against ballast impact, oil, UV and tunnel fire hazards

UIC552-PJ (Coach Fixed Junction-Box to UIC 552 Plug)

Standard coach-end configuration: one end bolted inside the coach HV junction box via M16/M20 compression lug & EMC gland, opposite end fitted with UIC 552 HV plug

UIC552-PP / DEPOT (Double-Ended or Depot Pre-Heating)

Double-ended UIC 552 plug-to-plug jumper or stationary depot pre-heating (Vorheizanlage) supply cable up to 25 m

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on UIC 552 / EN 50264-2-1 / EN 45545-2 HL3 / IEC 61373. Values for your order are confirmed in the datasheet and quotation.

Electrical

Nominal UIC 552 system voltages
1,000 V AC (16.7/50 Hz) · 1,500 V AC/DC · 3,000 V DC
Cable rated voltage (U0/U)
1.8/3 (3.6) kV or 3.6/6 (7.2) kV to EN 50264 / EN 50382
Rated continuous current
400 A (95 mm²) · 630 A (150 mm²) · 800 A (185/240 mm²)
Main contact resistance
≤ 0.15 mΩ (silver-plated lamellar / crown contact)
AC dielectric routine test
6.5 kV AC (1.8/3 kV) or 11.0 kV AC (3.6/6 kV) for 5 min

Thermal

Ambient operating range
−40 °C to +85 °C (silicone variant to +120 °C)
Max. short-circuit temperature
+250 °C (up to 40 kA dynamic peak)

Mechanical

Conductor cross-sections
95 mm², 120 mm², 150 mm², 185 mm² or 240 mm² Class 6
Safety interlock system
Mechanical key / pilot switch interlock per UIC 552
Shock & vibration
IEC 61373 Category 2 (coach headstock mounted)
Min. bend radius
5 × OD static · 6 × OD dynamic inter-coach loop

Resistance

Fire & smoke safety
EN 45545-2 HL3 (R15/R16)
Ingress protection
IP66 / IP67 mated in HV socket or dummy parking socket
Trackside environment
Ballast stone impact, ozone, mineral oil & acid wash

Reference standards

UIC interoperability
UIC Leaflet 552 / RIC Regulations
Rolling-stock HV cable
EN 50264-2-1 / EN 50264-3-1 / EN 50382-2
Electrical safety
EN 50153 rolling stock protective provisions

Identification

Housing warning mark
Permanent ISO 7010 High-Voltage Lightning Flash symbol
Jacket marking
TEBAOFLEX UIC 552 3.6/6kV EN 50264 EM104 EN 45545-2 HL3
Customs tariff (HS)
8544.60 / 8607.99

Sizes

12 standard UIC 552 high-voltage Head-End Power (HEP / ZS) jumper assemblies

Covers 95 mm² to 240 mm² Class 6 inter-coach jumpers (1,200–2,200 mm) and depot stationary pre-heating cables.

Cross-section, ampacity, length & weight
Order designationCross-Section & BuildMax Current
A		Cable U0/U
kV		Length
mm		Cable OD
mm		Assy Wt
kg		Enquiry
Inter-Coach UIC 552 Plug-to-Junction-Box (PJ) & Plug-to-Plug (PP) Jumpers
UIC552-PJ-1X95-15001×95 mm² Class 6 (Plug → Lug)425 A3.6/6 kV1,50024.55.2
UIC552-PJ-1X120-15001×120 mm² Class 6 (Plug → Lug)520 A3.6/6 kV1,50026.85.9
UIC552-PJ-1X150-15001×150 mm² Class 6 (Plug → Lug)630 A3.6/6 kV1,50029.06.7
UIC552-PJ-1X150-18001×150 mm² Class 6 (Plug → Lug)630 A3.6/6 kV1,80029.07.4
UIC552-PJ-1X185-15001×185 mm² Class 6 (Plug → Lug)800 A3.6/6 kV1,50031.57.8
UIC552-PJ-1X185-18001×185 mm² Class 6 (Plug → Lug)800 A3.6/6 kV1,80031.58.6
UIC552-PP-1X185-16001×185 mm² Class 6 (Plug ↔ Plug)800 A3.6/6 kV1,60031.510.2
UIC552-PJ-1X240-16001×240 mm² Class 6 (Plug → Lug)800 A+3.6/6 kV1,60035.09.8
Screened / Pilot-Monitored & Depot Pre-Heating UIC 552 Assemblies
UIC552-PJ-1X150C25-16001×150 mm² + 25 mm² Earth Screen630 A3.6/6 kV1,60031.27.6
UIC552-PJ-1X185C35-16001×185 mm² + 35 mm² Earth Screen800 A3.6/6 kV1,60033.88.9
UIC552-DEPOT-1X150-10M1×150 mm² + Pilot Depot Pre-Heat630 A3.6/6 kV10,00031.229.5
UIC552-DEPOT-1X185-15M1×185 mm² + Pilot Depot Pre-Heat800 A3.6/6 kV15,00033.849.0
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • All assemblies are routine dielectric-tested at 11.0 kV AC rms for 5 minutes and supplied with matching HV warning plates and test certificates.

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
11.0 kV AC 5-minute high-voltage dielectric testZero breakdown or flashover on finished jumper assembly100 % of assemblies
Micro-ohm contact & lug crimp resistance test≤ 0.15 mΩ across silver-plated contact and hex/indent lug crimp100 % of assemblies
Sample tests
800 A thermal-rise & 40 kA peak short-circuit withstand testVerify temperature rise within EN 50264 / UIC 552 limitsType approval

Inspection certificate

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

Product approvals

UIC Leaflet 552 / RIC High-Voltage Train Line CompliantEN 45545-2 HL3 & EN 50264-2-1 (3.6/6 kV) Certified

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX UIC 552 HV TRAIN LINE 3.6/6kV EN 50264 EM104 EN 45545-2 HL3
Packaging
Heavy-duty timber crate or carton with individual 11 kV HV test report
Coach hardware
Matching UIC 552 HV coach receptacles, safety interlock switches & dummy sockets
Custom lugs
M12, M16 or M20 DIN 46235 tinned copper compression lugs at 0° or 90°
Lead time
3–5 weeks ex-works

Technical documents

Downloads

PDFUIC 552 Jumper Assembly – technical datasheet12 sizes · construction, technical data, approvalsXLSXUIC 552 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.

Why must a UIC 552 jumper be rated up to 3,000 V and 800 A?
International RIC passenger coaches operate across all four European railway electrification systems: 1,000 V 16.7 Hz AC (Germany/Austria/Switzerland), 1,500 V 50 Hz AC / 1,500 V DC (France/Netherlands), and 3,000 V DC (Italy/Poland/Belgium/Spain). At 1,000 V or 1,500 V, a 14-coach train drawing 1.0–1.2 MW for HVAC and dining cars requires up to 800 A continuous current.
How does the UIC 552 safety interlock prevent personnel from unplugging a live 3,000 V jumper?
The UIC 552 receptacle cover is mechanically locked by a key-interlock or electromagnetic/pilot-loop interlock connected to the locomotive HV heating contactor. The receptacle latch can only be opened after the train-line earthing switch is closed or the pilot loop has opened the main breaker.
Why is Class 6 extra-fine stranding mandatory for 150 mm² and 185 mm² UIC 552 cables?
A standard Class 2 or Class 5 185 mm² copper conductor is far too stiff to flex in a 1.5 m inter-coach hanging loop and would fatigue the coach junction box. Class 6 stranding uses over 3,600 individual 0.25 mm tinned copper wires laid in rope-lay bundles so the cable swings freely even at −40 °C.
When should a concentric copper screen (e.g. 1×185C35) be specified?
Many national railway safety authorities (and EN 50153) require a concentric 25 mm² or 35 mm² tinned copper earth screen around the HV core so that any mechanical penetration (such as derailment debris or severe ballast damage) creates an immediate phase-to-earth fault that trips the locomotive breaker before anyone can touch the cable.

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UIC 552 Jumper Assembly

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