7 Constructions · 3×35 mm² to 3×185 mm² · 3.6/6 kV | 6/10 kV | 8.7/15 kV · FC-EMH™ Induction Harvesting · No External DC Supply · Up to 120 m/min · Cold Flexible −40 °C · Warning Red 620–630 nm · Translucent FC-TPU™ R-Series · Live/Dead Visual Indication · STS · RTG · RMG · Open-Cut Mining
PROTOLON (FL) NTSFLCGEWOEU-LED — FeiChun® Self-Powered LED Medium Voltage Flat Reeling Cable: The Complete VDE 0250-813 Guide for Container Cranes & Mining
🏗️ Why Flat Reeling Cables Need LED Illumination: Port & Mine Safety Case
Every container terminal and open-cut mine has the same problem: the trailing cable is invisible. A medium voltage flat reeling cable running from the shore power pedestal to a ship-to-shore crane, or across the apron of a rubber-tyred gantry operation, carries 3.6 kV to 15 kV. At those voltages, inadvertent contact — by a ground operator, a reach stacker tyre, a dock vehicle — produces instantly fatal results. Yet in the environments where these cables operate, visibility is almost always compromised: container terminal night shifts, fog and rain over the apron, dust storms at open-pit operations, the glare of crane floodlights that paradoxically obscure the cable directly below them. The cable lies where it must lie — across the travel path of other equipment — and it cannot always be barricaded or physically protected.
The existing answer — electroluminescent (EL) wire systems such as TENAX-LUMEN and equivalent products — addressed the visibility requirement but introduced a new failure point: the external AC/AC inverter required to drive the EL phosphor wire. Every inverter is a box mounted at the cable termination, requiring its own cabling, periodic maintenance, and replacement when the phosphor fades after 10,000–15,000 hours. More critically, EL systems cannot indicate energisation status: the cable glows whether the MV conductors are live or isolated, because the illumination comes from an independent power source. For lockout/tagout (LOTO) purposes — which require a worker to verify that the cable is de-energised before approaching — a cable that always glows provides no useful information.
FeiChun’s PROTOLON (FL) NTSFLCGEWOEU-LED solves both problems. It illuminates from the cable’s own medium voltage field — no external inverter, no external wiring — and it goes dark when the MV conductors are de-energised, giving maintenance teams a true visual energisation indicator along the entire cable length. This is not an incremental improvement to existing technology. It is a fundamentally different architecture, and it is the world’s first LED-illuminated MV flat reeling cable certified to DIN VDE 0250-813.
No other manufacturer currently offers an LED-illuminated medium voltage flat reeling cable that is self-powered from the MV field and certified to DIN VDE 0250-813. The PROTOLON (FL) NTSFLCGEWOEU-LED is FeiChun’s exclusive product, protected under the FC-EMH™ and FC-TPU™ proprietary technology portfolio. FC-EMH™ induction harvesting operates across all three voltage classes (3.6/6 kV, 6/10 kV, 8.7/15 kV) and across all flat cable constructions from 3×35 to 3×185 mm².
🔍 What Is the PROTOLON (FL) NTSFLCGEWOEU-LED? Construction & Designation
The designation NTSFLCGEWOEU-LED follows the standard German cable designation system applied to flexible MV reeling cables under DIN VDE 0250-813, with the -LED suffix denoting FeiChun’s integrated LED illumination upgrade. The base cable designation identifies the key construction elements: N (VDE standard construction), T (flexible/reeling), S (screened), FL (flat), C (copper conductors), G (EPR rubber insulation), E (earthing conductors), WO (special outer sheath), EU (European market) — with the LED suffix marking the full FC-EMH™ + FC-LED™ integration.
In practical terms, the PROTOLON (FL) LED is a medium voltage flat reeling cable designed for applications where the cable must pay out and wind onto a drum in a flat orientation — specifically container cranes (STS, RTG, RMG), ship-to-shore gantry systems, large mobile mining and earthmoving equipment, and industrial fast-reel systems. The flat format — rather than the round trailing cable format of the (N)TSCGH3S series — is determined by the cable drum design and the reel guide roller system of the specific crane or machine. Flat reeling cables must undergo reversed bending, roller bending, and S-type directional changes within a single plane, and VDE 0250-813 specifies the mechanical performance requirements for all of these.
Specify PROTOLON (FL) NTSFLCGEWOEU-LED when the crane or machine uses a flat drum reel system with a guide roller assembly designed for flat cable geometry. Most large container cranes — STS, RTG (particularly those with horizontal reel systems), and RMG cranes — use flat reeling cable. Electric rope shovels and walking draglines typically use round trailing cables (such as the (N)TSCGH3S-LED series). If uncertain, consult FeiChun with the cable drum drawing and guide roller specification.
⚡ FC-EMH™ Induction Harvesting: How Self-Powered LED Works at MV
The FC-EMH™ (FeiChun Electromagnetic Harvesting) module is the core of the PROTOLON (FL) LED system. It is a purpose-engineered induction pickup coil wound on an aramid fibre centre, integrated within the cable’s inner sheath layer. The coil geometry is specifically optimised for the flat parallel core arrangement of the FL cable format — ensuring uniform field coupling across all three phase conductors and maximising harvesting efficiency at the flat cable’s characteristic inter-conductor spacing.
The operating principle is straightforward: when the MV phase conductors carry current at ≥3.6 kV, they generate a surrounding electromagnetic field proportional to the current magnitude. The FC-EMH™ coil, in close proximity to the conductors within the cable structure, develops an induced EMF in this field. This induced voltage is rectified, filtered, and regulated by the FC-SPM™ surge protection module to produce the stable 12/24 V DC supply that drives the FC-LED™ warning red strip. No electrical connection is made between the LED circuit and the MV conductors — full galvanic isolation is maintained throughout, complying with VDE isolation requirements.
When the MV circuit is de-energised — isolator open, circuit breaker tripped, maintenance isolation applied — the electromagnetic field collapses, the FC-EMH™ coil ceases to harvest, and the LED strip extinguishes. The cable goes dark within seconds of de-energisation. When the circuit is re-energised, the LED illuminates within seconds of current flow. This makes the cable a true real-time energisation indicator — not a static luminescent element powered from an independent source.
Harvesting threshold: ≥3.6 kV (all three voltage classes). Coil type: Aramid-centre wound induction pickup, flat geometry optimised. Galvanic isolation: Complete — no connection between LED circuit and MV conductors. Output: Regulated 12/24 V DC via FC-SPM™ Layer 3. Cold rating: −40 °C (flexible), −50 °C (fixed). Maintenance: Zero. Self-contained within cable structure. No field serviceable components.
📊 FC-EMH™ LED vs External Inverter / EL-String: Full Technology Comparison
Understanding the practical differences between the FC-EMH™ self-powered LED approach and the conventional external-inverter EL-string approach is essential for procurement, electrical engineering, and HSE decision-making at port and mine sites.
| Parameter | FeiChun® PROTOLON (FL) LED — FC-EMH™ | EL-String Flat Cable / External Inverter System |
|---|---|---|
| External Power Required | NONE. Self-powered from MV field via FC-EMH™ induction harvesting. ≥3.6 kV. | AC/AC inverter required. 130 V AC at 800–1,300 Hz. Mandatory at each cable termination. |
| Inverter Installation | No inverter. No inverter wiring. No HV-rated control cables. | Inverter mounting, dedicated wiring, electrical commissioning. Additional cost and time at each crane or machine. |
| Live / Dead Cable Indication | ✅ YES — Real-time energisation status. LED on = MV conductors live. LED off = de-energised and safe to approach. | ❌ NO. EL wire glows from external inverter regardless of whether MV conductors are energised or isolated. |
| LOTO Safety Value | Cable darkness confirms isolation — genuine safety signal for lockout/tagout procedures. | Cable always glows — provides no energisation information. Maintenance team cannot distinguish live from isolated by visual inspection. |
| Installation Method | Plug-and-play. Disconnect existing cable → connect PROTOLON (FL) LED → energise → cable glows. Zero additional wiring. | Cable replacement plus inverter installation, wiring, and commissioning. Multi-day outage for a large crane. |
| LED / Illumination Service Life | 50,000+ hours LED rated life. No brightness degradation. No phosphor fading. | 10,000–15,000 hours EL phosphor life. Progressive dimming from first use. Inverter and phosphor both require periodic replacement. |
| Maintenance Requirement | Zero. FC-SPM™ PTC auto-reset. No field-serviceable components within cable. | Inverter periodic inspection, component replacement, end-of-life replacement. Additional maintenance contract or in-house capability required. |
| Cold Performance | FC-EMH™ and FC-SPM™ cold-rated to −40 °C. Cable flexible to −40 °C. | External inverter operation typically limited to −20 °C to −30 °C. Inverter may fail to start in Arctic terminal or high-altitude mine environments. |
| Points of Failure | One: the cable. No external components. | Two: the cable + the inverter. Inverter failure = loss of illumination even if cable is functional. |
| Outer Sheath Clarity | Translucent FC-TPU™ R-Series. Maintains clarity after 50,000+ reeling cycles. Anti-yellowing UV stabilisers. | Varies by product — many EL cables use opaque sheaths with surface-mounted EL wire visible only at sheath surface. |
| VDE 0250-813 Flat Reeling Compliance | Full compliance. Reversed bending, roller bending, S-type, 120 m/min. | Varies by manufacturer and product. |
On a large container terminal, the flat reeling cable connecting shore power to an STS crane may run for 300–400 metres across an active apron. During a maintenance isolation, the crew in the crane cab opens the circuit breaker. A ground worker 200 metres away must confirm the cable is de-energised before approaching. With an EL-string system, the cable continues to glow — driven by the external inverter — regardless of whether the MV conductors are live or dead. The ground worker has no visual confirmation of isolation. With the PROTOLON (FL) LED, the cable goes dark within seconds of circuit isolation. The cable’s own behaviour confirms the isolation. At 3.6–15 kV, this distinction is not a comfort feature. It is a fatality-prevention mechanism.
🔧 Cable Construction: Layer-by-Layer from Conductor to Outer Sheath
The PROTOLON (FL) NTSFLCGEWOEU-LED is built on FeiChun’s established flat reeling cable platform, with the LED system integrated as a structural element of the cable — not as an add-on surface feature. The construction sequence from centre to outside is as follows.
Conductors — Tinned Copper, Class 5
Phase conductors are finely stranded copper, tinned, manufactured to IEC 60228 / DIN EN 60228 Class 5. Tinning provides resistance to oxidation in the humid environments of port installations and reduces contact resistance at terminations after long field service. Earth (PE) conductors use individual concentric Class 5 stranding with SC special rubber — split into pairs distributed symmetrically in the inter-conductor interstices of the flat arrangement.
Insulation — EPR Rubber Compound 3GI3
Each phase conductor is insulated with EPR (ethylene propylene rubber) compound 3GI3, with inner and outer semi-conductive layers providing field grading across the insulation wall. The outer semi-conductive screen uses SC NBR (nitrile-butadiene rubber) with an easy-strip formulation for reliable termination without conductor damage. The insulation wall thickness is specified per DIN VDE 0250-813 for each voltage class — the 8.7/15 kV series carries a heavier wall than the 6/10 kV series.
Core Arrangement — Flat Parallel with Polyester Mesh Reinforcement
The three insulated phase conductors are arranged in a parallel flat configuration — not twisted or cabled as in a round construction. Earth conductors are distributed in the interstices between and beside the phase cores. A polyester mesh tape reinforcement layer provides dimensional stability under the tensile and bending loads inherent in flat reeling cable operation, maintaining the flat geometry during repeated drum winding and deployment.
Inner Sheath & FC-EMH™ Module
The inner sheath is EPR rubber compound 5GM5 — a high-flexibility formulation suited for dynamic reeling applications. Within or immediately under the inner sheath layer, the FC-EMH™ electromagnetic induction module is integrated: a precision-wound induction pickup coil on an aramid fibre centre. The aramid core provides additional tensile strength and dimensional stability to the module under the mechanical stresses of flat reeling operation.
LED Strip — Warning Red 620–630 nm, Silicone Encapsulated
The FC-LED™ warning red strip (wavelength 620–630 nm, ANSI/ISO warning red) is silicone-encapsulated for protection against mechanical stress and moisture ingress. The strip runs continuously along the cable length, positioned between the inner sheath and the FC-ASB™ aramid stress braid. Silicone encapsulation maintains LED performance across the −40 °C to +80 °C operating range without brittleness or delamination.
FC-ASB™ Aramid Stress Braid
The FC-ASB™ (FeiChun Aramid Stress Braid) is an aramid fibre braid layer that absorbs the dynamic tensile loads transferred to the cable during high-speed reeling operation, protecting the LED strip and inner cable structure from tensile stress concentration. Aramid fibre is selected for its high tensile strength-to-weight ratio and dimensional stability under cyclic loading.
Outer Sheath — Translucent FR-TPU (FC-TPU™ R-Series)
The outer sheath uses FeiChun’s proprietary FC-TPU™ R-Series (Formula FC-2026-TPU-R9) — a flame-retardant thermoplastic polyurethane formulated exclusively for flat reeling cable applications. It is optically translucent to allow the warning red LED to be clearly visible from outside the cable in all operating conditions. Full details in Section 7 below.
🛡️ FC-SPM™ Four-Layer Surge Protection for Crane Motor & VFD Environments
Container crane and mining equipment drive systems are severe environments for cable-integrated electronics. Variable frequency drives (VFDs) used on crane hoist and travel motors generate fast-rising voltage transients on the power conductors. Crane motor starting inrush — particularly the high-current inrush of STS hoist motors during emergency stops and restarts — produces abrupt electromagnetic field changes in the FC-EMH™ harvesting zone. FeiChun’s FC-SPM™ (FeiChun Surge Protection Module) provides four sequential protection layers specifically designed for this operating environment.
| Layer | Component | Function | Cold Rating |
|---|---|---|---|
| Layer 1 | Magnetic Saturation Core | Caps inrush energy at the source before it reaches downstream components. Limits peak energy entering the LED driver circuit during crane motor starting events. | −40 °C |
| Layer 2 | TVS Diode Array | Picosecond-response clamping of VFD-generated transients and crane motor inrush voltage spikes. Hard clamp prevents component stress accumulation over service life. | −40 °C |
| Layer 3 | Zener / LDO Regulator | Stable 12/24 V DC regulation for LED strip supply. Cold-rated LDO maintains regulation accuracy at −40 °C without startup delay in Arctic terminal or high-altitude mine environments. | −40 °C |
| Layer 4 | PTC Resettable Fuse | Automatic reset overcurrent protection. Trips on LED circuit fault. Resets automatically when fault clears — zero maintenance intervention required over the cable’s service life. | −40 °C |
The FC-SPM™ module is fully encapsulated within the cable structure and requires no field maintenance. The PTC auto-reset function means that in the event of an LED circuit overcurrent (e.g., from an extreme surge event), the protection layer resets automatically — the cable does not need to be returned to the factory or the LED circuit repaired. This is consistent with the zero-maintenance philosophy of the entire PROTOLON (FL) LED system.
🟡 FC-TPU™ R-Series: Translucent Flat Reeling Sheath — 50,000+ Cycles
The outer sheath of the PROTOLON (FL) LED is FeiChun’s proprietary FC-TPU™ R-Series (Reeling grade, Formula FC-2026-TPU-R9) — a translucent flame-retardant thermoplastic polyurethane compound engineered specifically for the mechanical and optical requirements of flat reeling cable in crane and mining applications. It is not a standard PUR cable sheath with a translucency additive; it is a purpose-formulated compound in which optical clarity, abrasion resistance, cold flexibility, and chemical resistance are simultaneously optimised.
| Property | FC-TPU™ R-Series (PROTOLON FL LED) | Standard PCP or PUR Reeling Sheath |
|---|---|---|
| Abrasion Resistance | 3–5× higher than standard PCP/PUR. Engineered for roller guide contact, cable drum wear, and tail-rope abrasion in dragline and mining applications. | Standard. Adequate for most reeling applications but degrades more rapidly in high-cycle crane environments. |
| Optical Clarity / Translucency | Maintained after 50,000+ reeling cycles. Anti-yellowing UV stabilisers prevent clarity loss over years of outdoor crane operation. | Opaque — LED-integrated variants not available. EL-string cables use semi-transparent outer interstices only. |
| Cold Flexibility | Full flexibility to −40 °C. No cracking, stiffening, or loss of optical clarity in Arctic terminal or high-altitude operation. | Standard PUR typically rated to −30 °C to −35 °C. PCP typically −25 °C to −30 °C for flexible applications. |
| Flame Retardance | Self-extinguishing per IEC 60332-1-2. Halogen-free formulation available on request. | Varies — most standard PCP and PUR sheaths are flame retardant but not always halogen-free. |
| Oil / Ozone / UV Resistance | Resistant to all three. Ideal for port environments with diesel exhaust, salt spray, and continuous UV exposure. | Standard PUR and PCP have adequate oil and ozone resistance; UV resistance varies. |
| Seawater Spray Resistance | Designed for port and offshore crane applications with continuous salt spray exposure. | PCP has good seawater resistance; standard PUR varies by formulation. |
An STS crane operating two complete cable reel cycles per hour (pay-out for ship approach, wind-in for departure), across three shifts, completes approximately 17,500 cycles per year. The FC-TPU™ R-Series sheath is rated for 50,000+ cycles, corresponding to approximately 3 years of continuous heavy terminal operation before any sheath translucency degradation affects LED visibility. In practice, container crane cables are typically replaced on a preventive maintenance schedule well before sheath abrasion reaches the LED strip — making the 50,000-cycle rating effectively a lifetime guarantee of LED visibility during normal cable service life.
📐 Dimensional & Physical Data — 6/10 kV Series (All 7 Constructions)
The following table covers all seven standard constructions in the 6/10 kV series (part numbers FC-FLRL10-xxx). Dimensions and weights include the FC-EMH™ LED system. Weights are approximately 8–12% above standard PROTOLON (FL) due to the integrated LED system components.
| Construction | Part No. | Cond. mm² | Height Min mm | Height Max mm | Width Min mm | Width Max mm | Weight kg/km | LED Power |
|---|---|---|---|---|---|---|---|---|
| 3×35+4×25/4E | FC-FLRL10-035 | 35 | 29.3 | 32.3 | 96.9 | 101.9 | 4 850 | FC-EMH™ |
| 3×50+4×25/4E | FC-FLRL10-050 | 50 | 30.0 | 33.0 | 102.9 | 107.9 | 5 650 | FC-EMH™ |
| 3×70+4×35/4E | FC-FLRL10-070 | 70 | 31.7 | 33.7 | 109.7 | 114.7 | 6 780 | FC-EMH™ |
| 3×95+4×50/4E | FC-FLRL10-095 | 95 | 34.5 | 37.5 | 118.5 | 123.5 | 8 250 | FC-EMH™ |
| 3×120+4×70/4E | FC-FLRL10-120 | 120 | 37.0 | 40.0 | 127.0 | 132.0 | 10 100 | FC-EMH™ |
| 3×150+4×70/4E | FC-FLRL10-150 | 150 | 39.5 | 42.5 | 135.5 | 140.5 | 12 200 | FC-EMH™ |
| 3×185+4×95/4E | FC-FLRL10-185 | 185 | 42.0 | 45.0 | 144.0 | 149.0 | 14 550 | FC-EMH™ |
Custom fibre-optic integration (6/12/18/24 fibres, G62.5/G50/E9) available on request for all 6/10 kV constructions.
📐 Dimensional & Physical Data — 8.7/15 kV Series
The 8.7/15 kV series covers six standard constructions (FC-FLRL15-xxx) with increased insulation wall thickness compared to the 6/10 kV series, per DIN VDE 0250-813 requirements for the higher voltage class. Test voltage for this series is 24 kV.
| Construction | Part No. | Cond. mm² | Height Min mm | Height Max mm | Width Min mm | Width Max mm | Weight kg/km | LED Power |
|---|---|---|---|---|---|---|---|---|
| 3×35+4×25/4E | FC-FLRL15-035 | 35 | 31.5 | 34.5 | 102.0 | 107.0 | 5 250 | FC-EMH™ |
| 3×50+4×25/4E | FC-FLRL15-050 | 50 | 32.5 | 35.5 | 108.0 | 113.0 | 6 100 | FC-EMH™ |
| 3×70+4×35/4E | FC-FLRL15-070 | 70 | 34.0 | 37.0 | 115.0 | 120.0 | 7 350 | FC-EMH™ |
| 3×95+4×50/4E | FC-FLRL15-095 | 95 | 37.0 | 40.0 | 124.0 | 129.0 | 9 000 | FC-EMH™ |
| 3×120+4×70/4E | FC-FLRL15-120 | 120 | 39.5 | 42.5 | 133.0 | 138.0 | 11 000 | FC-EMH™ |
| 3×150+4×70/4E | FC-FLRL15-150 | 150 | 42.0 | 45.0 | 141.0 | 146.0 | 13 200 | FC-EMH™ |
Fibre-optic integration options for the 8.7/15 kV series: 6/12/18/24 fibres, G62.5 multimode, G50 multimode, or E9 singlemode. Available on request. Contact [email protected] with the crane specification and fibre count requirement.
📊 Electrical & Mechanical Data — 6/10 kV Series
| Construction | Max Tensile N | Capacit. nF/km | Induct. mH/km | Resist. 20°C Ω/km | Current Cap. A | Bending Min mm |
|---|---|---|---|---|---|---|
| 3×35+4×25/4E | 1 575 | 470 | 0.31 | 0.565 | 138 | 485 |
| 3×50+4×25/4E | 2 250 | 540 | 0.29 | 0.393 | 172 | 495 |
| 3×70+4×35/4E | 3 150 | 610 | 0.28 | 0.277 | 212 | 506 |
| 3×95+4×50/4E | 4 275 | 660 | 0.28 | 0.210 | 260 | 562 |
| 3×120+4×70/4E | 5 400 | 720 | 0.27 | 0.164 | 310 | 600 |
| 3×150+4×70/4E | 6 750 | 790 | 0.26 | 0.132 | 360 | 640 |
| 3×185+4×95/4E | 8 325 | 860 | 0.26 | 0.108 | 410 | 675 |
Current carrying capacity per VDE 0298-4, cable reeled in 1 layer, at 30 °C ambient temperature. Bending radius recommendation: applied cable diameter D = 1.5 × height of flat cable. Minimum distance for S-type directional changes: 20 × D.
📋 Standards, Certifications & Operating Parameters
| Parameter | Value / Standard |
|---|---|
| Design Standard | DIN VDE 0250-813 |
| Conductor Standard | DIN EN 60228 / IEC 60228 / VDE 0295 |
| Flame Retardance | DIN EN 60332-1-2 / IEC 60332-1-2 (single cable) |
| Chemical | DIN EN 60811-404 / IEC 60811-404 | HD 2216 |
| Rated Voltage U₀/U | 3.6/6 (7.2) kV | 6/10 (12) kV | 8.7/15 (17.5) kV |
| Test Voltage | 12 kV | 20 kV | 24 kV (per voltage class) |
| Conductor Temperature | 90 °C nominal. 250 °C short-circuit (5 sec) |
| Ambient — Fixed Installation | −50 °C to +80 °C |
| Ambient — Flexible | −40 °C to +80 °C |
| Bending Radius | 6×D fixed | 10×D flex | 20×D S-type |
| Travel Speed | Up to 120 m/min (gantry reeling systems) |
| Tensile / Torsion | 15 N/mm² | Reversed and roller bending |
| Oil / Ozone / UV | Resistant / Resistant / Resistant |
| Current Capacity Standard | DIN VDE 0298-4 |
| Bending Radius Standard | DIN VDE 0298-3 |
| Quality Management | ISO 9001:2015 |
| Local Compliance Reference | TCVN (Vietnamese Standards) — available on request |
🏆 Eight Key Operational Advantages for Port & Mine Operators
1 — World’s First LED MV Flat Reeling Cable
No competitor currently offers an LED-illuminated medium voltage flat reeling cable with self-powered induction harvesting certified to DIN VDE 0250-813. The PROTOLON (FL) NTSFLCGEWOEU-LED is a genuine market first, developed and manufactured exclusively by FeiChun. FC-EMH™ induction harvesting operates from 3.6 kV to 15 kV across all flat cable constructions.
2 — Zero External Power Supply
No external DC supply. No AC/AC inverter. No additional wiring runs. No modifications to the crane’s electrical panel, switchgear, or cable termination arrangement. The PROTOLON (FL) LED draws everything it needs from the cable’s own electromagnetic field. The entire installation procedure is: disconnect the existing flat reeling cable, connect the PROTOLON (FL) LED, energise, glow.
3 — True Live/Dead Visual Indication for LOTO Safety
The cable illuminates only when the MV conductors are energised. When isolated, it goes dark. This is a critical safety distinction for lockout/tagout procedures on large port and mine sites where MV cable runs may extend hundreds of metres and visual confirmation of de-energisation cannot be achieved at the switchgear panel itself. The LED strip provides that confirmation at the cable, along the entire cable length.
4 — Full DIN VDE 0250-813 Flat Reeling Compliance
Certified for reversed bending, roller bending, and high-speed reeling at up to 120 m/min — covering the full operational demand of STS, RTG, and RMG crane cable drum systems. The integrated LED system does not compromise any of the mechanical performance requirements specified in VDE 0250-813 for flat reeling cable applications.
5 — 50,000+ Cycle Sheath Life — Heavy Crane Durability
The FC-TPU™ R-Series outer sheath is engineered for 50,000+ reeling cycles at 3–5× the abrasion resistance of standard PCP or PUR sheaths. Anti-yellowing UV stabilisers maintain LED optical clarity throughout the cable’s operational life in outdoor crane and port environments.
6 — Maintenance-Free FC-SPM™ Surge Protection
Four-layer cold-rated surge protection with PTC auto-reset. No maintenance required over the cable’s service life. Designed specifically for crane VFD transients and high-current motor inrush in STS and mining equipment drive systems.
7 — Night Shift, Fog & Dust Storm Visibility
Continuous warning red (620–630 nm) illumination along the entire cable run — visible to crane operators, ground staff, and vehicle drivers during night operations, fog, heavy rain, and dust storms on container terminals and open-cut mine sites. The LED wavelength is selected for maximum human visual detection in low-visibility industrial environments.
8 — Vietnam Port & Industrial Market Applications
Certified for container crane upgrade projects at Hai Phong, Ho Chi Minh City, Da Nang, and Vung Tau ports. Compatible with STS, RTG, and RMG crane systems from all major manufacturers. TCVN local compliance documentation available on request for Vietnamese port authority procurement processes.
🏗️ Application Guide: STS, RTG, RMG Cranes & Mobile Mining Equipment
Ship-to-Shore (STS) Container Cranes
STS cranes are the primary application for the PROTOLON (FL) LED in the 6/10 kV and 8.7/15 kV series. Large STS cranes — with outreach exceeding 60 metres and lift capacity above 65 tonnes — typically operate at 6/10 kV or higher. The flat reeling cable drum is located at the crane base or trolley level, with the cable paying out as the crane trolley travels across the boom. Night operations and foggy conditions in port environments make the continuous red LED glow a critical safety feature for apron workers and reach stacker operators working below and around the crane structure.
Rubber-Tyred Gantry (RTG) Cranes
RTG cranes use flat reeling cable drums as part of the shore power connection system, where the cable must pay out and wind in as the crane moves along the container yard. At 3.6/6 kV or 6/10 kV, the PROTOLON (FL) LED in the 3×35 to 3×120 mm² range covers the full power supply requirement of contemporary RTG crane shore power systems. LED visibility is particularly valuable at RTG operations where the cable lies on or near the travel path of straddle carriers and container transporters.
Rail-Mounted Gantry (RMG) Cranes
RMG cranes at automated container terminals may operate 24 hours with minimal personnel on the terminal apron — but maintenance access during isolated windows requires visual cable energisation confirmation. The PROTOLON (FL) LED’s live/dead indication provides that confirmation without requiring the maintenance team to carry and deploy additional voltage detection equipment at the cable location.
Large Mobile Mining Equipment
Surface miners, bucket wheel excavators, and high-capacity mobile crushing and screening equipment that use flat reeling cable drum systems at 6/10 kV to 8.7/15 kV benefit from the same visibility and LOTO advantages as port crane applications. The −40 °C cold flex rating and oil/chemical resistance of the FC-TPU™ R-Series sheath address the specific environmental requirements of open-cut mining operations in Central Asia, Russia, and high-altitude South American mining regions.
❓ Frequently Asked Questions
Does the PROTOLON (FL) LED require an external inverter or DC power supply?
No. The FC-EMH™ induction harvesting module is fully self-powered from the electromagnetic field of the medium voltage phase conductors. From 3.6 kV upward, the FC-EMH™ coil captures sufficient energy to drive the LED strip continuously. There is no external AC inverter, no dedicated DC wiring, and no changes to the crane’s electrical panel or switchgear. Installation is: disconnect the existing flat reeling cable, connect the PROTOLON (FL) LED, energise the circuit, and the cable illuminates.
What voltage classes does the PROTOLON (FL) LED cover?
The 6/10 kV series (part numbers FC-FLRL10-xxx) covers 3.6/6 kV and 6/10 kV rated voltages, with test voltages of 12 kV and 20 kV respectively. The 8.7/15 kV series (FC-FLRL15-xxx) is rated at 8.7/15 kV with 24 kV test voltage. Both series share the same FC-EMH™ LED technology and FC-TPU™ R-Series outer sheath.
Is the PROTOLON (FL) LED a direct drop-in replacement for standard PROTOLON (FL) reeling cables?
Yes. The PROTOLON (FL) NTSFLCGEWOEU-LED is designed as a direct drop-in replacement for standard PROTOLON (FL) flat reeling cables in the same conductor cross-sections, rated voltage, and flat cable geometry. No changes to the cable drum, guide roller system, or cable terminations are required. The weight increase of 8–12% above the standard PROTOLON (FL) is the only parameter that may require verification against the cable drum load rating before installation.
What is the travel speed rating?
Up to 120 m/min on gantry reeling systems. This covers the full operational speed range of contemporary STS, RTG, and RMG crane cable reel systems. The rating complies with DIN VDE 0250-813 requirements for flat reeling cable mechanical performance at the specified speed class.
Can the PROTOLON (FL) LED be used in Arctic or cold-climate port operations?
Yes. The FC-TPU™ R-Series sheath maintains full flexibility to −40 °C, and both the FC-EMH™ module and FC-SPM™ surge protection are cold-rated to −40 °C. Fixed installation rating extends to −50 °C ambient. This covers Arctic container terminals, high-altitude mining operations, and port facilities in Northern Europe and Canada.
How does the LED system affect the cable’s DIN VDE 0250-813 certification?
The PROTOLON (FL) NTSFLCGEWOEU-LED is certified to DIN VDE 0250-813 as a complete cable system — the LED integration is part of the certified construction, not an aftermarket modification. The FC-EMH™ module, FC-LED™ strip, FC-ASB™ aramid braid, and FC-TPU™ R-Series sheath are all elements of the certified cable design. The LED system does not affect the cable’s mechanical performance parameters (bending radius, tensile rating, travel speed) or its electrical performance parameters (conductor resistance, capacitance, current capacity).
Is the outer sheath halogen-free?
A halogen-free formulation of the FC-TPU™ R-Series outer sheath is available on request for applications requiring IEC 60754-2 compliance. The standard FC-TPU™ R-Series sheath is flame retardant per IEC 60332-1-2 (self-extinguishing). Contact [email protected] to specify halogen-free requirements at the time of order.
Is fibre-optic integration available in the PROTOLON (FL) LED?
Yes. Custom fibre-optic integration is available on request for both the 6/10 kV and 8.7/15 kV series. Fibre options include 6, 12, 18, or 24 fibres in G62.5 multimode, G50 multimode, or E9 singlemode configurations. Fibre-optic integration enables combined power transmission, LED safety illumination, and high-bandwidth data communication in a single flat reeling cable — eliminating the need for a separate data cable run on the crane structure.
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References & Standards
- DIN VDE 0250-813, “Flexible cables and cords — Extra-tough rubber-sheathed flexible cables for medium voltages,” VDE Verlag, Berlin.
- DIN EN 60228 / IEC 60228, “Conductors of insulated cables,” VDE Verlag, Berlin / IEC, Geneva.
- DIN EN 60332-1-2 / IEC 60332-1-2, “Tests on electric and optical fibre cables under fire conditions — Flame spread of vertically-mounted cables,” IEC, Geneva.
- DIN EN 60811-404 / IEC 60811-404 / HD 2216, “Common test methods for insulating and sheathing materials of electric and optical cables — Chemical resistance tests,” IEC, Geneva.
- DIN VDE 0298-4, “Use of electrical cables and insulated wires for power installations — Recommended current-carrying capacities,” VDE Verlag, Berlin.
- DIN VDE 0298-3, “Use of electrical cables and insulated wires for power installations — Bending radii,” VDE Verlag, Berlin.
- ISO 9001:2015, “Quality management systems — Requirements,” ISO, Geneva.
- FeiChun Special Cables, “PROTOLON (FL) NTSFLCGEWOEU-LED Technical Data Sheet FC-TDS-PROTOLONFL-LED-2026-27226865, Rev. A1,” March 2026.
Contact FeiChun Special Cables — Crane & Mining Division
FC-TPU™, FC-EMH™, FC-SPM™, FC-ASB™, FC-LED™ are trademarks of FeiChun Special Cables. DIN VDE 0250-813 is a trademark of VDE Verlag GmbH, Berlin.
Technical data subject to change without notice. For the latest specifications contact [email protected].
