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EN 45545-2 Requirements For Railway Cables

EN 45545-2 Fire Protection Standard for Railway Vehicles

1. Scope & Classification

  • Application Focus: Materials/components for railway vehicles (R15 for in-vehicle cables, R16 for out-vehicle cables)

  • Hazard Levels:

    • HL1: Lowest risk (e.g., low-density urban transit)

    • HL2: Medium risk (e.g., regional trains)

    • HL3: Highest risk (e.g., underground/subway systems)

2. Key Performance Requirements

Test Category Test Standard HL1 HL2 HL3
Smoke Density IEC 61034-2 (Light Transmittance) In-vehicle: ≥25% Out-vehicle: ≥0% In-vehicle: ≥50% Out-vehicle: ≥25% In-vehicle: ≥70% Out-vehicle: ≥50%
Flammability IEC 60332-1 (Single vertical burn) Pass Pass Pass
IEC 60332-3-24/EN 50305 (Bundle test)* Class B Class A Class A
Toxicity EN 50305 ≤3.5mg/g ≤3.0mg/g ≤2.5mg/g

*Bundle test selection based on cable diameter

3. Critical Technical Distinctions

  • In-Vehicle vs Out-Vehicle Cables:

    • Smoke density requirements are 25-40% stricter for in-vehicle cables

    • Same flammability/toxicity thresholds for both types

    • Out-vehicle cables may require additional UV/weather resistance

  • Material Considerations:

    • HL3 cables typically use ceramic-former insulation

    • Low-smoke zero-halogen (LSZH) compounds mandatory for all levels

    • Additional acid gas emission limits (≤5% HCl equivalent)

4. Testing Protocol

  1. Pre-conditioning: Cables aged at 120°C for 240h (simulating service life)

  2. Sequential Testing:

    • Flammability → Smoke density → Toxicity

    • All tests performed on same sample batch

  3. Compliance Thresholds:

    • Must meet ALL criteria for designated HL level

    • No compensation between test categories

Industry Implementation

  • HL3 Adoption: Now mandatory for all new metro projects in EU (2023 directive)

  • Cost Impact: HL3 cables cost 35-50% more than HL1 equivalents

  • Emerging Solutions:

    • Silicone-based insulation for high HL3 compliance

    • Modular cable trays with integrated fire barriers

This standard represents the most stringent fire safety requirements for mass transit applications, with HL3 effectively becoming the new baseline for urban rail systems worldwide. Manufacturers must carefully validate material formulations against the complete test matrix - passing individual tests doesn't guarantee overall compliance.