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Heat Trace Contact Rail Heater (CRH)

Manufacturer: Heat Trace Ltd.

Self-Regulating Heating Cable for Contact Rails, Third Rails and Rail Heating Applications

Product Overview

The Heat Trace Contact Rail Heater (CRH) is a specialist self-regulating electric heating cable developed for contact rails, conductor rails and third rails operating in railway electrification systems. It is designed to prevent snow and ice accumulation on current-carrying rails, helping maintain the operational integrity and reliability of rail networks during adverse winter weather conditions.

The CRH heating cable automatically adjusts its heat output in response to changes in surface temperature. This self-regulating characteristic helps provide heat where required as rail temperatures change, supporting effective ice prevention in demanding outdoor railway environments.

Designed for railway applications involving traction power systems up to 750 V DC, the CRH is suitable for heating contact and live rails. It can also be considered for replacing compatible existing rail heaters, including discontinued TLT (Thermolimit TLT Series) cables by nVent Raychem, subject to verification of electrical, mechanical and installation compatibility.

The cable can be supplied in pre-terminated lengths of up to 376 metres, with a 1.5-metre cold lead and remote-end seals. It can be cut to the required length in accordance with the manufacturer's instructions and is designed for installation using protective glass-reinforced plastic (GRP) channel or angle sections and purpose-made heavy-duty rail clips.

Key Features and Benefits

• Self-regulating heating technology that automatically adjusts heat output as surface temperature changes.
• Designed for contact rails, conductor rails and third-rail heating applications.
• Helps prevent snow and ice accumulation on railway current-carrying rails.
• Suitable for railway traction systems operating up to 750 V DC, subject to system design.
• Power supply capability of up to 1000 V AC or DC, according to the product specification.
• Can be cut to the required length in accordance with approved installation procedures.
• Available in single lengths of up to 376 metres.
• Supplied with a 1.5-metre pre-terminated cold lead and remote-end seals.
• Designed to withstand severe and continuous vibration caused by rail traffic.
• Suitable for exposure to snow, icy water, diesel oils, lubrication oils, weed-killer formulations, oxalic acid and de-icing fluids, subject to the manufacturer's specifications.
• Capable of operating fully or partially in free air without adversely affecting the heater's working life, as specified by the manufacturer.
• Designed for quick installation and replacement with minimum disruption to railway traffic.
• Suitable for direct replacement of compatible existing contact-rail heating systems.

Technical Specifications

Applications

• Ice prevention on contact rails in railway networks.
• Snow and ice prevention on third rails and live conductor rails.
• Winter protection of railway electrification infrastructure.
• Heating of compatible rail sections exposed to freezing temperatures.
• Replacement of compatible existing contact-rail heating cables.
• Railway maintenance projects requiring reliable heating under harsh outdoor conditions.

Installation and Mounting

The CRH cable is secured to the rail using a protective glass-reinforced plastic (GRP) channel or angle section together with purpose-made heavy-duty rail clips. The mounting arrangement is designed to hold the heater in position while accommodating the demanding mechanical conditions encountered in railway environments.

The cable is designed for straightforward installation and replacement, helping minimise track possession time and disruption to railway traffic. Its ability to operate fully or partially in free air provides flexibility for approved rail-heating arrangements without requiring the heater to be completely enclosed in thermal insulation.

The heating cable must be terminated using approved cold-lead connections, end seals and compatible accessories. Installation, electrical connections, protection devices, testing and commissioning must comply with the manufacturer's installation instructions and the applicable railway and electrical safety requirements.

Recommended Accessories

• UTK 344 termination accessory.
• BPS4 power seal kit.
• BES4 end seal kit.
• DESTU Seal No. 5.
• Commercial junction box with knockouts (CMJB).
• Compatible rail clips and protective GRP channel or angle sections.
• Approved temperature-control and electrical-protection equipment, where required by the system design.

Replacement Compatibility

The Heat Trace CRH is designed to replace compatible existing contact-rail heaters and can integrate with many existing contact-rail and live-rail heating systems. It may be considered as a replacement for discontinued TLT (Thermolimit TLT Series) heating cables by nVent Raychem.

Before replacing an existing heater, verify the electrical ratings, cable dimensions, heat output, termination method, mounting arrangement, circuit length, protective devices and applicable system approvals. A replacement must be confirmed as technically compatible with the specific rail profile and operating conditions.

Design and Safety Considerations

Correct system design requires consideration of the rail temperature, minimum ambient temperature, local snowfall and icing conditions, required heating output, supply voltage, start-up temperature and circuit-breaker characteristics. Maximum circuit length and protective-device selection must be determined using the manufacturer's approved design data for the selected cable and operating conditions.

The cable and its accessories must be suitable for the environmental conditions at the installation site, including vibration, moisture, ice, diesel oils, lubrication oils and de-icing chemicals. The specified minimum bending radius must be respected, and the cable must be protected from mechanical damage during installation and maintenance.

Product Summary

The Heat Trace Contact Rail Heater (CRH) is a specialist self-regulating heating cable designed to prevent snow and ice accumulation on contact rails, conductor rails and third rails. Its automatic heat-output adjustment, cut-to-length capability, robust construction and suitability for demanding railway environments make it a practical solution for railway winter protection and compatible rail-heater replacement projects.

With a nominal power output of up to 130 W/m, a maximum withstand and energised temperature of 250°C, a minimum installation temperature of -40°C and a maximum supply rating of up to 1000 V AC or DC, the CRH can be evaluated for a range of rail-heating requirements. Final selection must be based on the manufacturer's technical documentation, circuit design, rail configuration and applicable safety requirements.