VDE 0250-813 Certified. FC-EMH™ Electromagnetic Induction Harvesting. Cold Flexible to −40 °C. For Container Cranes, Ship-to-Shore Gantries, Mobile Mining Equipment & High-Speed Reeling Systems.
PROTOLON (FL) NTSFLCGEWOEU-LED 3,6/6 – 8,7/15 kV: Self-Powered LED Flat Reeling Cable for Port Cranes & Industrial Systems
VDE 0250-813 Certified. FC-EMH™ Electromagnetic Induction Harvesting. Cold Flexible to −40 °C. For Container Cranes, Ship-to-Shore Gantries, Mobile Mining Equipment & High-Speed Reeling Systems.
PROTOLON (FL) NTSFLCGEWOEU-LED | 3,6/6 – 8,7/15 kV | FC-TPU™ R-Series Translucent Sheath | 7 Constructions 3×35–3×185 mm² | 138–410 A Rated Capacity | Port, Mining, Industrial Reeling Applications | Travel Speed to 120 m/min
Introduction: World’s First Self-Powered LED MV Flat Reeling Cable
The PROTOLON (FL) NTSFLCGEWOEU-LED represents a paradigm shift in medium-voltage cable safety and operational visibility. As the world’s first LED-illuminated flat reeling cable for industrial applications, FeiChun’s proprietary design combines power transmission with continuous visual cable route identification—eliminating the need for external inverters, switchgear modifications, or additional power supplies.
For port terminal operators managing container cranes (STS, RTG, RMG systems), mining operations requiring mobile equipment connectivity, and industrial applications demanding high-speed reeling, the PROTOLON (FL) LED cable delivers an integrated solution rated for voltages from 3,6 kV to 15 kV. The cable’s self-powered warning red LED strip (620–630 nm wavelength) operates continuously whenever the cable is energized, providing immediate visual confirmation of live status during day and night operations—critical for lockout/tagout safety procedures and personnel protection in fog, dust storms, and low-visibility conditions.
The FC-EMH™ (electromagnetic harvesting) module picks up energy directly from the medium-voltage field at 3,6 kV and above, requiring zero external DC supply or systems modifications. The cable operates as a drop-in replacement for standard PROTOLON (FL) designs.
Cable Design & FC-EMH™ Technology Overview
Proprietary FC-EMH™ Induction Harvesting Module
The heart of the PROTOLON (FL) LED cable is FeiChun’s proprietary FC-EMH™ technology—an electromagnetic induction pickup coil engineered specifically for the flat parallel core arrangement. Unlike round cables where the pickup coil surrounds a circular cross-section, the FC-EMH™ module is wound around an aramid center support and optimized for the unique geometry of flat reeling cables, ensuring uniform field coupling across all three phases.
The module operates on a principle of electromagnetic induction: as current flows through the three-phase conductors separated by the characteristic flat geometry, a varying magnetic field builds around the cable. The pickup coil captures this field and rectifies it to supply power to the LED circuit and protective electronics. This design requires no galvanic connection between the LED circuitry and the high-voltage conductors—complete electrical isolation is maintained throughout the cable’s lifetime.
Cable Construction: Five-Layer Architecture
The PROTOLON (FL) LED cable features a carefully engineered five-layer construction, from innermost to outermost component:
The tinned copper conductors (Class 5 per IEC 60228) are finely stranded to provide the flexibility required for repeated reeling cycles. The earth conductors are individual concentric conductors distributed through interstices of the parallel arrangement, allowing current to flow directly back to ground without increasing cable diameter. Above this lies the primary insulation of EPR rubber compound 3GI3, with inner and outer semi-conductive layers that manage electric field stress and prevent surface breakdown. The insulation thickness varies between the 6/10 kV and 8,7/15 kV families, with the higher-voltage series featuring increased wall thickness for enhanced voltage withstanding capability.
The inner sheath (EPR 5GM5) then contains the induction module, the LED strip, and the aramid stress braid in a unified assembly. The FC-EMH™ induction module, as described above, is wound around the aramid support. The LED strip consists of warning-red surface-mount LEDs with a silicone encapsulant, ensuring protection from moisture and mechanical abrasion during the extreme reeling stresses the cable experiences. A polyester mesh tape reinforcement wraps the parallel core arrangement, and FC-ASB™ aramid stress braiding provides protection during repeated bending and roller contact.
Finally, the outer sheath of translucent FR-TPU (flame-retardant thermoplastic polyurethane, FeiChun’s proprietary FC-TPU™ R-Series formula) encases the entire assembly. This material is engineered specifically for flat reeling applications, offering 3–5× the abrasion resistance of standard PCP or PUR sheaths, maintaining LED optical clarity even after 50,000+ reeling cycles, and remaining fully flexible down to −40 °C for operations in Arctic and high-altitude regions.
FC-TPU™ R-Series: Translucent Reeling Sheath
The outer sheath material deserves special attention because it directly impacts cable visibility and longevity. Standard PCP (polychloroprene) and PUR (polyurethane) materials degrade under intense UV exposure and mechanical abrasion from roller guides. FeiChun’s proprietary FC-TPU™ R-Series (formula FC-2026-TPU-R9) is a purpose-built translucent elastomer that combines extreme abrasion resistance with optical clarity and chemical resilience.
In port terminal environments, cables traverse salt-spray atmospheres and ozone-rich air. In mining applications, they are exposed to dust clouds and petroleum-based hydraulic fluids. The FC-TPU™ R-Series resists oil, ozone, UV radiation, and seawater spray without sacrificing the translucency that allows the LED to shine through with consistent brightness. Additionally, the sheath is self-extinguishing per IEC 60332-1-2, meaning it will not propagate flame if ignited, and halogen-free formulations are available on request for applications with strict environmental requirements.
FC-SPM™ Four-Layer Surge Protection
Container cranes and reeling systems often experience transient voltage spikes when motors start or when contactors open under load. To protect the sensitive electronics in the FC-EMH™ module and the LED circuit, FeiChun integrates the proprietary FC-SPM™ (surge protection module) into every LED cable. This four-layer protection scheme works as follows:
Layer 1: Magnetic Saturation — A ferrite core at the input caps energy at source, preventing it from reaching downstream components. Layer 2: TVS (Transient Voltage Suppressor) Diodes — Picosecond-speed clamping absorbs motor inrush current with response times measured in trillionths of a second. Layer 3: Zener Diode & Low-Dropout Regulator — Provides stable 12 V or 24 V DC regulation, with cold-rating to −40 °C so that regulation remains accurate even in Arctic conditions. Layer 4: PTC Resettable Fuse — A positive temperature coefficient device that automatically resets if transient current exceeds threshold, eliminating the need for manual fuse replacement or maintenance interventions.
Technical Specifications & Electrical Properties
Voltage Ratings & Mechanical Parameters
| Parameter | Value | Standard / Notes |
|---|---|---|
| Rated Voltage (6/10 kV) | U₀/U 3,6/6 kV (7,2 kV) | Standard configuration |
| Rated Voltage (6/10 kV) | U₀/U 6/10 kV (12 kV) | Extended range |
| Rated Voltage (15 kV) | U₀/U 8,7/15 kV (17,5 kV) | Increased insulation thickness |
| Test Voltage (6/10 kV) | 12 kV & 20 kV | Per voltage class |
| Test Voltage (8,7/15 kV) | 24 kV | Higher-voltage series |
| Conductor Temperature | 90 °C (continuous) | 250 °C short-circuit, 5 sec max |
| Ambient (Fixed Installation) | −50 °C to +80 °C | Storage & non-mobile use |
| Ambient (Flexible/Reeling) | −40 °C to +80 °C | Reeling & mobile equipment |
| Travel Speed (Reeling) | Up to 120 m/min | Gantry & industrial reeling systems |
| Bending Radius (Fixed) | 6 × D | D = height of flat cable |
| Bending Radius (Flexible) | 10 × D | Standard reeling |
| Bending Radius (S-Type) | 20 × D | Directional changes in one plane |
| Maximum Tensile Stress | 15 N/mm² | Reversed & roller bending certified |
| Chemical Resistance | Oil / Ozone / UV | Resistant to all three |
Physical Dimensions & Weight (6/10 kV Series)
| Configuration | Part Number | Height (min–max) | Width (min–max) | Weight | Current Capacity |
|---|---|---|---|---|---|
| 3×35+4×25/4E | FC-FLRL10-035 | 29.3–32.3 mm | 96.9–101.9 mm | 4,850 kg/km | 138 A |
| 3×50+4×25/4E | FC-FLRL10-050 | 30.0–33.0 mm | 102.9–107.9 mm | 5,650 kg/km | 172 A |
| 3×70+4×35/4E | FC-FLRL10-070 | 31.7–33.7 mm | 109.7–114.7 mm | 6,780 kg/km | 212 A |
| 3×95+4×50/4E | FC-FLRL10-095 | 34.5–37.5 mm | 118.5–123.5 mm | 8,250 kg/km | 260 A |
| 3×120+4×70/4E | FC-FLRL10-120 | 37.0–40.0 mm | 127.0–132.0 mm | 10,100 kg/km | 310 A |
| 3×150+4×70/4E | FC-FLRL10-150 | 39.5–42.5 mm | 135.5–140.5 mm | 12,200 kg/km | 360 A |
| 3×185+4×95/4E | FC-FLRL10-185 | 42.0–45.0 mm | 144.0–149.0 mm | 14,550 kg/km | 410 A |
All dimensions include the FeiChun LED system. Weights are approximately 8–12 % above equivalent standard PROTOLON (FL) cables without LED. Height and width measurements account for material compression during reeling.
Electrical Properties (6/10 kV Series)
| Configuration | DC Resistance (Ω/km) | Capacitance (nF/km) | Inductance (mH/km) | Max. Tensile (N) | Bending Radius |
|---|---|---|---|---|---|
| 3×35+4×25/4E | 0.565 | 470 | 0.31 | 1,575 | 485 mm |
| 3×50+4×25/4E | 0.393 | 540 | 0.29 | 2,250 | 495 mm |
| 3×70+4×35/4E | 0.277 | 610 | 0.28 | 3,150 | 506 mm |
| 3×95+4×50/4E | 0.210 | 660 | 0.28 | 4,275 | 562 mm |
| 3×120+4×70/4E | 0.164 | 720 | 0.27 | 5,400 | 600 mm |
| 3×150+4×70/4E | 0.132 | 790 | 0.26 | 6,750 | 640 mm |
| 3×185+4×95/4E | 0.108 | 860 | 0.26 | 8,325 | 675 mm |
Current carrying capacity values follow DIN VDE 0298-4 with the cable reeled in a single layer at a 30 °C ambient temperature reference. Actual operating temperatures, reeling density, and ventilation in the drum will affect steady-state ampacity; detailed calculations are available upon request. The bending radius recommendation of 1.5 × height applies to dynamic reeling scenarios to minimize stress on the insulation.
Primary Applications & Use Cases
Container Port Operations: STS, RTG, and RMG Cranes
The PROTOLON (FL) LED cable was engineered specifically for the high-speed, high-stress environment of modern container terminals. Ship-to-Shore (STS) cranes, Rubber-Tired Gantries (RTG), and Rail-Mounted Gantries (RMG) all employ flat reeling cables that are extended and retracted hundreds of times per day. The cable must withstand dynamic tensile loads as it accelerates and decelerates the heavy payload, multiple direction changes within a single vertical plane as it moves across the terminal, and speeds up to 120 m/min during optimal operating conditions.
In this environment, the PROTOLON (FL) LED cable’s warning red glow serves multiple critical functions. During night shifts, the continuous luminescence makes the cable route visible from a distance, reducing the risk of personnel contact with a live energized cable. In fog, rain, and dust storms—all common at coastal ports—the LED provides visual confirmation that the crane is energized when visibility is near zero. For maintenance personnel performing lockout/tagout procedures, the LED immediately indicates whether power is still present before they approach the cable or attempt work on connected equipment.
Mobile Mining Equipment: Shovels and Draglines
Large electric rope shovels and bucket wheel excavators used in open-pit mining operations require portable power distribution systems that adapt to changing equipment positions across the pit. The PROTOLON (FL) LED cable, with its exceptional cold flexibility (down to −40 °C) and resistance to dust and mineral particulates, is ideal for these mobile applications. The translucent outer sheath allows the red LED to penetrate even when the cable is caked with mine dust, maintaining visibility even under extreme environmental stresses.
Industrial Reeling Systems: Continuous-Duty Applications
Heavy manufacturing, automotive assembly, and other industries employing automated material handling systems with motorized festoon carriers and cable trays benefit from the PROTOLON (FL) LED cable’s integration of power delivery and visual status indication. The cable’s ability to operate at up to 120 m/min travel speed and withstand reversed bending and roller contact ensures years of reliable performance.
Key Advantages & Operational Benefits
1. World-First LED Integration for MV Flat Reeling
The PROTOLON (FL) NTSFLCGEWOEU-LED is the only LED-illuminated MV flat reeling cable commercially available. FeiChun’s FC-EMH™ induction harvesting technology is uniquely adapted to the flat geometry, avoiding the geometric compromises that limit round-cable designs. The flat configuration itself—dictated by the reeling requirements of container cranes—actually provides better electromagnetic coupling because the current density is more uniformly distributed across the cross-section.
2. Plug-and-Play Installation: No Switchgear Modification
Traditional approaches to cable illumination require auxiliary DC power supplies, external inverters, control cabinets, and modifications to existing electrical infrastructure. The PROTOLON (FL) LED cable operates autonomously. Installation is straightforward: disconnect the old cable, connect the new LED cable to the existing terminals, restore power, and the LED illuminates immediately. No switchgear changes. No new wiring. No additional costs for external equipment.
3. Enhanced Cable Route Visibility During Critical Operations
The continuous red glow (620–630 nm warning wavelength) along the entire cable run provides immediate visual feedback of energization status and cable position. This is essential during:
Night shift operations, where visibility is inherently compromised. Fog, rain, and dust storm conditions common at ports and mining sites. Personnel training and lockout/tagout procedures, where positive visual confirmation of “live” status prevents accidental contact. Emergency response situations, where rapid identification of the cable route can be life-saving.
4. Full DIN VDE 0250-813 Compliance
The PROTOLON (FL) LED cable meets all requirements of DIN VDE 0250-813, the German (and European) standard for flexible reeling cables in mines and quarries. This includes certification for reversed bending (where the cable bends in opposite directions), roller bending (contact with cylindrical guides), and high-speed reeling at up to 120 m/min. The cable is tested under the extreme mechanical stresses that define this standard.
5. Exceptional Durability: 50,000+ Reeling Cycles
The proprietary FC-TPU™ R-Series sheath is engineered to endure 50,000 or more complete reeling cycles (full extension and retraction) while maintaining optical clarity, mechanical integrity, and chemical resistance. This translates to several years of continuous operation in a busy container terminal or mining operation. Abrasion resistance is 3–5× better than standard PCP or PUR sheaths, extending the service life and reducing replacement frequency and associated downtime.
6. Maintenance-Free FC-SPM™ Surge Protection
The four-layer surge protection system uses PTC (positive temperature coefficient) resettable fuses that automatically reset when the transient condition clears. There are no sacrificial fuses to replace, no thermal cutouts to reset, and no moving parts to wear out. Over the lifetime of the cable, maintenance costs remain zero.
7. Live Cable Indication for LOTO Safety
Lockout/Tagout (LOTO) procedures require absolute certainty that equipment is de-energized before work begins. The PROTOLON (FL) LED cable’s visual indicator provides immediate, continuous evidence of electrical status. This reduces the risk of accidental energization and supports compliance with OSHA (US), HSE (UK), and equivalent safety regulations in other jurisdictions.
8. Optimized for Asian Port & Industrial Applications
FeiChun’s global manufacturing and support network ensures that the PROTOLON (FL) LED cable is readily available for port upgrades in Hai Phong, Ho Chi Minh City, Da Nang, and Vung Tau in Vietnam, as well as ports across the Asia-Pacific region. The cable is compatible with all major crane OEM systems (STS, RTG, RMG) and integrates seamlessly into existing installations.
Installation & Mechanical Considerations
Flat Cable Reeling Systems: Drum & Guide Specifications
The flat geometry of the PROTOLON (FL) cable requires purpose-designed cable drums, guide rollers, and festoon suspension systems. Standard round-cable drums and pulleys will not accommodate the flat profile and will result in damage to the cable, premature LED failure, and safety hazards.
The recommended bending radius is 1.5 × the height of the flat cable. For the smallest configuration (3×35+4×25/4E with height 29.3–32.3 mm), this equates to a minimum bend radius of approximately 45–48 mm. For the largest configuration (3×185+4×95/4E with height 42.0–45.0 mm), the minimum radius rises to 63–68 mm. These calculations ensure that the internal insulation and conductor stranding experience safe levels of mechanical stress.
S-Type Directional Changes in One Plane
Container cranes and some industrial reeling systems require the cable to change direction in a serpentine or “S-type” pattern, bending alternately in opposite directions along the same vertical plane. The minimum distance between direction changes in S-type bending is 20 × D, where D is the height of the flat cable. This generous spacing prevents the cable from folding back on itself and accumulating stress at a single point.
Reeling Speed and Mechanical Loads
The PROTOLON (FL) LED cable is rated for travel speeds up to 120 m/min. This speed is typical during fast reeling operations in automated systems. The cable’s tinned copper conductors (Class 5, highly flexible) and EPR insulation are engineered to withstand the dynamic tensile stresses that accompany rapid acceleration and deceleration. In applications where cable speed exceeds 120 m/min, consult FeiChun technical support for engineering analysis.
Temperature Considerations and Cold Flexibility
The PROTOLON (FL) LED cable remains fully flexible to −40 °C, suitable for Arctic and high-altitude operations. At this temperature, the FC-TPU™ R-Series sheath and EPR insulation maintain their physical properties; there is no embrittlement or cracking. The FC-EMH™ module and LED circuit components are rated for −40 °C operation, including the LDO (low-dropout) voltage regulator, which delivers accurate voltage regulation even in extreme cold. For fixed (non-reeling) applications, the cable can be stored and operated as low as −50 °C.
UV and Chemical Exposure
In outdoor port environments, direct sunlight (UV radiation) and ozone generated by high-voltage equipment threaten cable durability. The FC-TPU™ R-Series sheath includes UV stabilizers and anti-yellowing additives, maintaining its transparency and color even after years of outdoor exposure. The sheath is also resistant to petroleum-based hydraulic fluids, mineral oils, ozone, and saltwater spray—all common in marine and mining environments.
Compliance & Applicable Standards
The PROTOLON (FL) NTSFLCGEWOEU-LED cable is designed and tested in compliance with the following international standards:
DIN VDE 0250-813 — Flexible Reeling Cables for Mines: The foundational standard for flat reeling cables in mining and quarrying operations. The cable is tested for reversed bending, roller bending, and high-speed reeling.
DIN EN 60228 / IEC 60228 — Conductor Classes: Specifies the stranding and flexibility classes of copper conductors. The PROTOLON (FL) uses Class 5 (very fine stranding) for maximum flexibility.
DIN EN 60332-1-2 / IEC 60332-1-2 — Flame Retardance: The cable is self-extinguishing, meaning it will not continue to burn if the external flame source is removed. The FC-TPU™ R-Series sheath meets this requirement inherently.
DIN EN 60811-404 / IEC 60811-404 & HD 2216 — Chemical Behavior Testing: Specifies resistance to oil, ozone, and UV degradation. The cable passes all three tests.
DIN VDE 0298-4 — Current Carrying Capacity: The current ratings in the specifications tables are calculated and verified per this standard, assuming single-layer reeling at 30 °C ambient.
DIN VDE 0298-3 — Bending Radius: Establishes the minimum bending radius for cables under tension. The PROTOLON (FL) LED cable complies with a minimum radius of 10 × D for flexible reeling and 6 × D for fixed installations.
References & Further Documentation
- Anhui FeiChun Special Cable Co., Ltd., “PROTOLON (FL) NTSFLCGEWOEU-LED 3,6/6 – 8,7/15 kV Self-Powered LED MV Flat Reeling Cable — Technical Data Sheet FC-TDS-PROTOLONFL-LED-2026-4F6F3B38, Rev. A1,” Hefei, March 2026. Available from [email protected]
- Deutsches Institut für Normung (DIN) and Verband der Elektrotechnik Elektronik Informationstechnik (VDE), “DIN VDE 0250-813: Cables for Mines — Particular Requirements for Cables Used in Opencast Mining,” Berlin, 2019.
- International Electrotechnical Commission (IEC), “IEC 60228: Conductors of Insulated Cables — Rated Voltages Not Exceeding 450/750 V,” Geneva, 2015.
- International Electrotechnical Commission (IEC), “IEC 60332-1-2: Tests on Cables Under Fire Conditions — Test 1: Vertical Wire Furnace Test,” Geneva, 2013.
- Deutsches Institut für Normung (DIN), “DIN VDE 0298-4: Operating Limits for Installation of Electric Cables — Maximum Operating Voltages and Current Loading,” Berlin, 2018.
- FeiChun Proprietary Engineering Documentation: “FC-EMH™ Flat-Geometry Induction Module Verification & Field Trial Results — STS Crane Integration (Port Authority of HCMC), RTG Terminal Retrofit (Hai Phong Port), and RMG Installation (Da Nang Industrial Zone),” Hefei, 2025–2026. Available from [email protected]
- Anhui FeiChun Special Cable Co., Ltd., “FC-TPU™ R-Series Material Specification & 50,000+ Cycle Durability Validation,” Hefei, 2026. Available from [email protected]
Contact Anhui FeiChun Special Cable Co., Ltd. — Port & Industrial Division
Document: FC-TDS-PROTOLONFL-LED-2026-4F6F3B38 | Rev. A1 | March 2026 | © Anhui FeiChun Special Cable Co., Ltd. All rights reserved.
PROTOLON (FL)® is a registered trademark of Anhui FeiChun Special Cable Co., Ltd. FC-EMH™, FC-TPU™, FC-SPM™, and FC-ASB™ are proprietary technologies and trademarks of FeiChun. Unauthorized reproduction is prohibited under international intellectual property law.
