Continuous-Flex Low-Smoke Halogen-Free CAT 5e Railway Ethernet Cable
This continuously flexible CAT 5e Ethernet cable is designed for moving data connections in rail vehicles and transportation equipment. Fine-stranded conductors, a movement-resistant halogen-free insulation system and combined foil-and-braid screening provide reliable transmission under repeated bending, elevated temperatures and demanding outdoor or underfloor conditions.
Key Highlights
Continuous-flex construction · CAT 5e transmission · Railway-oriented design · Low-smoke halogen-free materials · Star-quad and twisted-pair options · Foil-and-braid screening · Oil and fuel resistance · Outdoor suitability · Ozone, UV and weather resistance · −40°C flexible temperature rating · 15 × diameter continuous-flex radius · Suitable for EtherCAT and EtherNet/IP · Optional M12 or RJ45 assemblies · PFAS-free material option
Recommended for continuously moving railway data connections exposed to light or medium mechanical stress.
Typical applications include:
- Moving door-control systems
- Flexible connections inside rail vehicles
- Protected outdoor routing near bogies
- Connections installed in protective tubes
- Passenger information equipment
- Train monitoring and diagnostic systems
- Surveillance and ticketing equipment
- EtherCAT and EtherNet/IP networks
- Applications exposed to oil, fuel, weather and repeated bending
This cable is designed for continuous bending. It is not automatically suitable for torsional robot movement unless a separate torsion test has been completed.
Cable assemblies with M12 or RJ45 connectors are available on request.
Conductor: Fine-stranded bare copper
Core insulation: Special low-smoke, halogen-free flexible compound
Core identification:
- Two-pair versions: Blue, yellow, white and orange
- Four-pair versions: White-blue/blue, white-orange/orange, white-green/green and white-brown/brown
Data-element formation:
- Two-pair versions: Star-quad construction
- Four-pair versions: Cores twisted into pairs, with pairs laid together
Wrapping: Foil
Overall screen: Aluminium-laminated foil and tinned-copper wire braid
Outer sheath: Special low-smoke, halogen-free continuous-flex railway compound
Standard sheath color: Green, similar to RAL 6018
Cable shape: Round
Product category: Continuously flexible CAT 5e Industrial Ethernet cable
Peak operating voltage: Maximum 90 V
Test voltage:
- Core to core: 750 V
- Core to screen: 750 V
Characteristic impedance:
- Two-pair configurations: 100 Ω ±5 Ω
- Four-pair configurations: 100 Ω ±10 Ω
Transmission reference: EN 50288-2-2 / Category 5 reference requirements
Minimum bending radius:
- Fixed installation: 5 × cable diameter
- General flexible movement: 12 × cable diameter
- Continuous-flex application: 15 × cable diameter
Temperature range:
- Fixed installation: −50°C to +90°C
- Flexible application: −40°C to +90°C
Reference halogen-free performance:
- EN 50306-1
- EN 50264-1
- IEC 60754-1
- IEC 60754-2
- Fluorine content reference according to IEC 60684-2
Reference fire performance:
- No flame propagation according to IEC 60332-3-24 or IEC 60332-3-25
- Flame-retardant and self-extinguishing according to IEC 60332-1-2
- Smoke-density reference according to IEC 61034
- Toxicity reference according to EN 50305
Railway fire-performance reference: R15 (EL1A) and R16 (EL1B) according to EN 45545-2 for hazard levels HL1–HL3
Vehicle flame-performance reference: ISO 6722 / UN ECE R118
Oil and fuel resistance reference: EN 50264-1
Environmental resistance: Good resistance to ozone, ultraviolet radiation, weather, acids, alkaline solutions and aggressive chemicals
Installation environment: Suitable for protected interior and outdoor installation
Network compatibility reference: Suitable for EtherCAT and EtherNet/IP applications
Environmental compliance reference: RoHS and PFAS-free material options
| Pair Configuration | Maximum Insulated Core Ø | Approx. Outer Ø | Copper Weight | Approx. Cable Weight |
| 2 × 2 × 24 AWG | 1.25 mm | 5.1 mm | 22.8 kg/km | 40 kg/km |
| 2 × 2 × 22 AWG | 1.55 mm | 5.8 mm | 29.2 kg/km | 53 kg/km |
| 4 × 2 × 24 AWG | 1.29 mm | 7.8 mm | 42.3 kg/km | 81 kg/km |
| 4 × 2 × 26 AWG | 0.99 mm | 6.5 mm | 29.7 kg/km | 55 kg/km |
Final outer-diameter tolerances must be confirmed against the approved production drawing. Other configurations and sheath colors are available on request.
THE FACTORY
BEHIND EVERY METER
Founded in 2007 in Foshan, Guangdong, Hulk Electric has grown from a regional producer into a globally recognised manufacturer of customised industrial cable solutions. Our 10,000㎡ facility runs on Toyota Production System lean principles, operated by 150+ skilled professionals producing over 300,000 metres every month.
Every cable you see on this page — including the HK-TRVV series — is engineered, extruded, tested, and shipped from that single facility. No trading company sits between you and the extrusion line.
Source Factory
Direct manufacturer — no middlemen, no markups. You deal with the engineers who run the line.
Deep Customization
Conductor, shielding, jacket compound, colour coding, certification — built to your exact spec.
7-Day Sampling
Rapid samples for new specifications. 15-day lead time on standard production orders.
Global Compliance
35+ certifications covering UL, CE, TÜV, IEC, RoHS and REACH for every major market.
BEFORE YOU ORDER
For stocked configurations listed in the ordering table, MOQ is 100 metres per specification. Custom configurations — non-standard core counts, jacket colours, or special compounds — carry a 500 metre MOQ. Samples of 5–10 metres are available free of charge for qualification testing.
Use shielded (P or PP suffix) whenever the cable runs alongside servo drives, VFDs, or inverters, or when carrying encoder, sensor, or analogue signals. Unshielded is suitable for pure power distribution and simple on/off control lines. If in doubt, our engineering team can review your cabinet layout and advise — this is included with any quotation.
Yes. Send us the existing part number or a sample and we will produce a cross-reference specification with matching electrical, mechanical, and dimensional characteristics. Most cross-references are turned around within 3 working days, with a physical sample following within 7 days.
Standard shipments include the CE Declaration of Conformity, RoHS and REACH statements, and the batch test report. UL Recognition (UL 2464 / UL 20549) is available on request for North American projects — specify this at the quotation stage as it affects the material specification.
Standard configurations ship in 15 working days from order confirmation. Custom-engineered specifications typically require 20–25 working days, depending on compound availability. Rapid sampling for new specifications is 7 days. We will confirm the exact date in writing with your order acknowledgement.
SEND US YOUR
SPECIFICATION
Tell us your core count, cross-section, and application — our engineering team will confirm the right configuration and send pricing within one working day.
Your information is used only to prepare your quotation and is never shared with third parties.
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