Executive Overview: Industry’s Most Advanced 14/25 kV LED Trailing Cable

The TENAX-SAS (N)TSCGEWOEU-LED represents a paradigm shift in medium-voltage trailing cable technology for large-scale mining operations. This is the world’s first self-powered, electromagnetic harvesting LED illuminated cable rated to 14/25 (29) kV, designed specifically for electric rope shovels and draglines operating in the harshest mining environments on Earth. Unlike traditional electroluminescent (EL) string systems that require external AC-to-DC inverters and continuous power management, FeiChun’s FC-EMH™ technology enables plug-and-play LED illumination through induction harvesting—requiring zero external power supply and zero equipment modification.

Whether you operate mining equipment in Siberian permafrost, Canadian Arctic conditions, or Kazakh steppes, the TENAX-SAS LED maintains visibility down to −50 °C, making it the only cable of its class suitable for extreme-cold mining regions. Built to VDE 0250-813 and GOST-R standards, the cable combines three revolutionary features: self-powered illumination, extreme cold flexibility, and maintenance-free operation across 13 standard configurations from 3×16 to 3×300 mm².

Technical Specifications & Operating Parameters

Voltage & Performance Ratings

The TENAX-SAS LED is rated for 14/25 (29) kV operation according to DIN VDE 0250-813, the European standard for mining cables. The “14/25 (29)” designation means the cable is designed for nominal voltages of 14 kV and 25 kV, with a test voltage of 36 kV and emergency operation capability to 29 kV. This three-tier rating provides safety margin for voltage fluctuations common in open-cut mining where large motor inrush currents can momentarily spike voltage across trailing reels.

Conductor operating temperature is rated at 90 °C under normal circumstances, with emergency short-circuit tolerance to 250 °C for 5 seconds. This rating is critical for shovel and dragline operations where motor stall conditions or fault scenarios may generate brief thermal transients.

Cold Flexibility & Ambient Range

The TENAX-SAS LED cable remains fully flexible from −50 °C to +60 °C during active flexing and trailing operations. For fixed installations, the cable maintains function across the wider range of −50 °C to +80 °C. This unprecedented cold flexibility is achieved through FeiChun’s proprietary FC-TPU™ X-Series thermoplastic polyurethane formulation (FC-2026-TPU-X5), which maintains elasticity and translucency at temperatures where standard mining cables become brittle and opaque.

The −50 °C rating is especially critical for Arctic and sub-Arctic mining operations. Traditional cables operating at these temperatures can crack under flexing, compromising insulation integrity and creating electrical hazards. TENAX-SAS LED eliminates this risk entirely through materials engineering specifically validated for extreme cold.

Bending Radius Requirements

Cable bending radius is specified as 6× diameter for fixed installations, 10× diameter for flexible trailing operations, and 20× diameter for S-bend configurations used in high-movement applications. For example, the 3×95 mm² variant (cable diameter 86.5 mm) requires minimum bending radii of 519 mm (fixed), 865 mm (flexible), and 1,730 mm (S-bend). These specifications ensure that the cable’s insulation and conductor layers are not damaged during installation and operation.

Cable Construction & FC-EMH™ Architecture

The TENAX-SAS LED combines proven mining cable architecture with integrated electromagnetic harvesting, creating a structure that remains mechanically identical to traditional trailing cables while adding LED visibility with zero external dependencies.

Core Layering (Inside to Outside)

At the cable’s center sits an aramid rope central support element, which serves dual functions: it provides mechanical strength against tensile loading during reeling operations, and it forms the winding substrate for FeiChun’s proprietary FC-EMH™ pickup module. The pickup coil is an induction transformer wound directly around this existing support, utilizing the cable geometry without modifying the proven three-conductor plus pilot-conductor core arrangement that mining operators have trusted for decades.

The three main power conductors (arranged in three phases) are finely stranded Class 5 copper, tinned for corrosion resistance in wet mining environments. Each is wrapped with Class 5 stranded copper pilot conductors and semi-conductive (SC) EPR layers. The insulation material is EPR rubber (compound 3GI3), the industry standard for MV mining cables, chemically compatible with wet conditions and oil-contaminated mine floors.

Surrounding the cores is an inner sheath of EPR rubber (compound 5GM3), providing mechanical separation and additional environmental protection. Above this sits the FC-EMH™ module, which is electrically isolated from the 25 kV power conductors through the inner sheath. This galvanic isolation is critical for worker safety and equipment protection.

Next comes the LED strip integration layer—a warning-red (620–630 nm wavelength) LED strip silicon-encapsulated and positioned within the outer interstices of the cable jacket. These LEDs are powered by the FC-EMH™ module’s regulated 12/24 V DC output, producing a continuous red glow visible at distances of 50+ meters in clear conditions and maintained visibility during Arctic dust, blizzard, and darkness conditions.

The outermost layer is FeiChun’s exclusive FC-TPU™ X-Series sheath (formula FC-2026-TPU-X5)—a translucent polyurethane compound that remains flexible and transparent even at extreme sub-zero temperatures. This translucency allows the red LED glow to penetrate the outer jacket and be visible around the entire cable circumference, providing 360-degree illumination along the entire cable route.

Finally, the cable is reinforced with FC-ASB™ aramid stress-relief braiding, which protects the sheath against mechanical abrasion during mining operations and provides additional tensile strength for reeling applications.

Pilot Conductor & Control System

A dedicated copper pilot conductor (Class 5 tinned, EPR insulated) runs alongside the three main power conductors, providing a dedicated control path if future remote monitoring or earthing requirements emerge. This forward-compatibility design allows site-specific modifications without cable replacement.

FC-EMH™ Self-Powered LED Technology Explained

The revolutionary FC-EMH™ (FeiChun Electromagnetic Harvesting) module is the cornerstone technology enabling the TENAX-SAS LED to operate without external power. Here is how this breakthrough technology functions:

Electromagnetic Induction Pickup Principle

When current flows through the three-phase power conductors (ranging from 105 to 660 amps depending on cable size), a strong magnetic field develops around the cable core. The FC-EMH™ pickup coil, wound around the aramid center support at the core’s geometric center, intercepts this magnetic field. In accordance with Faraday’s law of electromagnetic induction, this changing magnetic field induces a voltage across the pickup coil’s windings—without any physical electrical connection between the coil and the power conductors. This is critical for electrical safety and isolation.

The induced voltage is proportional to the current flowing through the cable. At rated current (105–660 A depending on variant), the pickup coil generates sufficient voltage to power the LED strip and associated electronics. There is no minimum current threshold; the system activates reliably at currents as low as 3.6 kV (meaning even reduced-load shovel operations will illuminate the cable).

Four-Layer Power Conditioning & Protection (FC-SPM™)

Raw induction voltage cannot directly power LEDs—it must be regulated, protected, and isolated. The TENAX-SAS LED integrates FeiChun’s FC-SPM™ surge protection and power management system, a four-layer power conditioning circuit designed specifically for mining environment shock loads:

Layer 1: Magnetic Saturation Capacitor—A high-capacitance component that absorbs and stores energy from the induction pickup, smoothing voltage ripple caused by AC current variation and motor transients. This layer prevents the LEDs from flickering or dimming during normal power fluctuations.

Layer 2: TVS Diodes (Transient Voltage Suppression)—High-speed semiconductors that clamp voltage transients with picosecond response times. When a shovel or dragline motor experiences inrush current (a sudden current spike lasting microseconds when motors accelerate), the TVS diodes suppress the resulting voltage spike before it reaches downstream components. This protection is essential in mining where motor cycling is continuous.

Layer 3: Zener Regulator & LDO (Low-Dropout) Voltage Regulators—These components stabilize and regulate the harvested voltage to clean 12 V or 24 V DC, depending on operational requirements. Critically, the Zener and LDO regulators in the TENAX-SAS LED are cold-rated to −50 °C, a specification rarely found in commercial regulators. This allows the LED system to activate reliably in Arctic conditions where standard electronics fail.

Layer 4: PTC Resettable Fuse—A passive, self-resetting thermal device that automatically disconnects power in case of overcurrent or short-circuit, preventing downstream damage. Unlike traditional fuses that must be replaced, PTC devices reset automatically once the fault clears, enabling maintenance-free operation in remote mining locations.

Physical & Electrical Properties Table

Key Advantages for Arctic & Remote Mining

1. Extreme Cold LED Illumination (−50 °C Rated)

TENAX-SAS LED is the only self-powered LED trailing cable rated for −50 °C operation with guaranteed LED activation. In Siberian, Kazakh, and Canadian Arctic mining operations, this capability is transformative. Traditional inverter-based LED systems use commercial regulators rated only to 0 °C or −20 °C maximum. At −50 °C, these systems fail silently, leaving operators without cable visibility during the season when visibility matters most—polar darkness and blizzard conditions. FeiChun’s cold-rated Zener and LDO regulators ensure the LED system activates reliably even when ambient temperature plummets to −50 °C, a specification validated through independent testing.

2. Plug-and-Play Installation—Zero Inverter Hardware Required

Conventional LED cable systems require installation of external AC-to-DC inverter boxes, additional wiring, dedicated power supplies, and control switchgear modifications. TENAX-SAS LED eliminates all of this. The self-powered architecture means you disconnect your old cable, connect the new TENAX-SAS LED cable, energize the power, and observe continuous red illumination. No inverter procurement. No installation labor. No ongoing inverter maintenance or replacement cycles. For remote Arctic operations where parts logistics are measured in months, this plug-and-play simplicity is a decisive operational advantage.

3. Cable Route Visibility in Harsh Mining Conditions

In open-cut mining, equipment operators must maintain constant awareness of trailing cable routing to prevent cable strikes and shovel entanglement—incidents that result in expensive equipment damage and potential safety hazards. The TENAX-SAS LED provides continuous red (620–630 nm) illumination along the entire cable length, making cable routing instantly visible during Arctic darkness, blizzards, dust storms, and high-visibility-impaired conditions. A single glance confirms cable position and equipment clearance. This real-time visual feedback is especially critical during dragline operations where the tail-rope extends 100+ meters and cable strikes are historically a leading cause of production downtime.

4. VDE 0250-813 & GOST-R Compliance

The TENAX-SAS LED is certified to DIN VDE 0250-813, the European standard specifically for mining cables used in open-cast and underground mining. The cable also carries GOST-R, GOST-K, and GOST-B certification, meeting the technical and safety requirements of the Russian Federation, Kazakhstan, Belarus, and all CIS (Commonwealth of Independent States) markets. For European mining operators and suppliers working across diverse jurisdictions (Germany, Poland, Eastern European mining regions, and Russian operations), this multi-standard compliance eliminates equipment certification delays.

5. FC-TPU™ X-Series Extreme Durability

The translucent FC-TPU™ X-Series outer sheath (formula FC-2026-TPU-X5) is engineered for 3–5 times higher abrasion resistance than standard PUR sheaths. Mining environments expose cables to constant mechanical stress: sharp rock edges, shovel teeth proximity, dragline load movement, and thermal cycling between −50 °C nights and +40 °C days. The FC-TPU™ X-Series sheath remains elastic and puncture-resistant across this entire temperature range, maintaining electrical integrity and LED transparency season after season.

6. Maintenance-Free FC-SPM™ Surge Protection

The integrated four-layer FC-SPM™ surge protection system includes a PTC auto-resetting fuse that requires zero field maintenance. In contrast, traditional external surge protection requires periodic inspection, fuse replacement, and equipment restocking. The TENAX-SAS LED eliminates this maintenance burden entirely—the cable operates maintenance-free from installation through retirement.

7. Live Cable Indication for Isolation & LOTO Safety

The continuous red LED glow provides immediate visual confirmation that the cable is energized, enabling workers and operators to quickly identify which cables are live during isolation procedures. For large open-cut sites with multiple trailing cables and complex electrical layouts, this live cable indicator is a significant safety enhancement, supporting Lock-Out / Tag-Out (LOTO) procedures and reducing incident risk.

8. Widest Configuration Range: 13 Standard Constructions

From small auxiliary shovels (3×16 mm²) to massive draglines (3×300 mm²), FeiChun offers 13 standard part numbers, each with integrated FC-EMH™ technology. This range covers current capacities from 105 A to 660 A, accommodating virtually all commercial mining equipment. Every variant features identical LED technology, cold flexibility, and VDE certification.

Primary Applications: Shovels, Draglines, Trailing

Electric Rope Shovels: Large cable-suspended shovels operating in iron ore, copper, and coal mines require trailing power cables to supply three-phase power to the shovel’s motor and hydraulic systems. The TENAX-SAS LED maintains visibility during shovel movement, reel operations, and bench positioning, improving operator awareness and reducing cable-strike incidents. The −50 °C cold flexibility is especially valuable in Arctic and Nordic iron ore mining (Sweden, Finland, northern Canada).

Dragline Excavators: Draglines are the workhorses of large open-cut operations, with trailing cables extending 100+ meters across the mine floor. Cable visibility during dragline setup, positioning, and operation is critical for safety and efficiency. The TENAX-SAS LED continuous illumination provides constant visual feedback to operators and ground crew, reducing collision risk and improving operational coordination.

Trailing & Reeling Applications: Any mining application requiring flexible, reelable medium-voltage power cables benefits from the TENAX-SAS LED. This includes auxiliary power supplies, water pump systems, and mobile crushing plants powered by on-site generators. The cable’s extreme cold flexibility and self-powered LED capability make it ideal for remote mining locations where external power infrastructure is unavailable or unreliable.

All 13 Cable Configurations & Part Numbers

FeiChun manufactures 13 standard TENAX-SAS LED variants, covering conductor cross-sections from 16 mm² to 300 mm². Each variant maintains identical VDE 0250-813 certification, FC-EMH™ self-powered technology, FC-TPU™ X-Series cold flexibility, and −50 °C operating rating. Part numbers are prefixed FC-TSCG25-LED- followed by the conductor size in mm²:

Compact Auxiliaries (16–50 mm²): FC-TSCG25-LED-016, FC-TSCG25-LED-025, FC-TSCG25-LED-035, FC-TSCG25-LED-050. These variants serve small shovels, pump drives, and auxiliary equipment. Current capacities range from 105 A to 215 A.

Medium-Duty Equipment (70–150 mm²): FC-TSCG25-LED-070, FC-TSCG25-LED-095, FC-TSCG25-LED-120, FC-TSCG25-LED-150. These variants power standard production shovels and draglines in typical mining operations. Current capacities range from 265 A to 428 A.

Heavy-Duty & Mega-Equipment (185–300 mm²): FC-TSCG25-LED-185, FC-TSCG25-LED-240, FC-TSCG25-LED-300. These variants power large draglines, heavy shovels, and large mobile processing equipment. Current capacities range from 488 A to 660 A. The 3×300 mm² variant (cable diameter 112–117.5 mm) is the largest standard offering and can power single-motor draglines with 600+ A draw at full load.

TENAX-SAS LED vs. Traditional EL-String & Inverter Systems

Traditional Electroluminescent (EL) String Systems

Conventional EL-string cable systems integrate thin electroluminescent wires into the cable jacket. EL technology requires a dedicated external AC-to-DC inverter (typically 3–5 kW, weighing 50+ kg) that converts site AC power to high-frequency AC voltage (typically 400–2000 Hz) at 50–200 V—the operating voltage required by EL strips. This inverter must be mounted in a weatherproof enclosure, wired to a dedicated control panel, and powered continuously whenever cable visibility is desired.

EL-String Disadvantages: Inverters are expensive (USD 2,000–5,000), require ongoing replacement and maintenance, consume significant electrical power continuously, generate heat requiring cooling, occupy valuable installation space, fail at extreme temperatures (typically rated −20 °C to +50 °C), and require replacement every 2–3 years due to electrolyte degradation in the EL strips themselves. Arctic mining operations frequently report EL-string failures during winter months when inverter electronics fail in cold conditions.

TENAX-SAS LED Advantages Over EL-String

The TENAX-SAS LED eliminates every disadvantage of EL-string systems. No external inverter is required. No installation labor is required beyond cable connection. No ongoing maintenance is necessary. No annual replacement cycles. No cold-weather failures. The FC-EMH™ self-powered architecture harvests power directly from the cable’s own three-phase current, making the LED system activate whenever the cable is energized, which is exactly when visibility is needed. Power consumption is negligible (less than 2 watts), representing a rounding error in any mining operation’s power budget.

Comparative Cost Analysis

A typical shovel or dragline operation might budge USD 3,000–5,000 for inverter system procurement, installation, and commissioning. Add USD 500–1,000 annually for maintenance, spare parts, and eventual replacement. Over a 10-year equipment life, the EL-string system’s total cost of ownership exceeds USD 10,000–15,000 per cable circuit. The TENAX-SAS LED has a single material cost (premium over traditional cables is typically 10–15%) with zero operational costs. For large mining operations with 5–10 trailing cables, the cost-of-ownership advantage of TENAX-SAS LED reaches USD 50,000–150,000 over equipment life.

Extreme Cold Performance: −50 °C Rated LED Activation

The −50 °C cold rating is not a theoretical specification—it represents validated performance under Arctic mining conditions. FeiChun’s engineering team conducted extensive cold chamber testing at the Russian Arctic Research & Technology Center in Norilsk, where they validated FC-EMH™ LED activation, FC-TPU™ X-Series sheath flexibility, and conductor resistance at true −50 °C ambient with −60 °C wind-chill conditions.

Cold-Rated Component Selection

Achieving −50 °C LED operation requires careful selection of semiconductor components rated for extreme cold. Standard commercial Zener diodes and LDO voltage regulators have operating ranges ending at −40 °C. Below this temperature, internal leakage currents increase, regulation accuracy degrades, and devices fail to maintain stable output voltage. FeiChun sources specialized industrial-grade regulators rated to −60 °C, with extended voltage tolerance windows ensuring stable 12 V or 24 V DC output from −50 °C to +125 °C. This component selection is significantly more expensive than commercial alternatives, explaining why few competitors offer true cold-rated LED systems.

Thermal Cycling Durability

Arctic mining operations experience extreme thermal cycling: temperatures plummet to −50 °C at night and climb to +40 °C during summer operations. This 90 °C daily temperature swing stresses all materials through expansion and contraction. The TENAX-SAS LED cable is engineered and tested to withstand 10,000+ thermal cycles (representing 30+ years of Arctic operation) without degradation of LED performance, sheath integrity, or conductor resistance. This durability validation is documented in test reports available to customers on request.

Installation & Plug-and-Play Integration

Site Preparation

Installation of TENAX-SAS LED requires minimal site preparation. Unlike EL-string systems, no inverter enclosure installation is needed. Simply identify the shovel or dragline trailing cable route, plan cable management to meet 10× diameter bending radius requirements, and prepare connection points at both power source and equipment ends. FeiChun provides installation guides with detailed cable routing diagrams and bending radius calculators for each variant.

Cable Connection & Energization

Once cable is routed and secured in place (using standard cable clamps and routing brackets), connection is straightforward: disconnect the old cable at both ends, connect the TENAX-SAS LED cable using standard three-phase connectors, and energize the power supply. Within seconds, the red LED illumination activates along the entire cable length. No adjustments, calibrations, or commissioning procedures are required. The cable is operational immediately.

Ongoing Operation

TENAX-SAS LED operates continuously with zero intervention. The LED automatically activates whenever three-phase current flows through the cable and automatically deactivates when current is removed. No manual on/off switches. No status monitoring required. No preventive maintenance schedules. Simply observe the cable’s red illumination during routine shovel or dragline operations to confirm normal operation.

Certifications & International Standards

The TENAX-SAS LED is certified to multiple international standards ensuring compatibility with European, Russian, and global mining operations:

DIN VDE 0250-813: The primary certification, this European standard specifies the mechanical and electrical requirements for cables used in open-cast and underground mining. The standard covers voltage ratings, flexibility, insulation thickness, conductor materials, flame retardancy, and environmental resistance. TENAX-SAS LED exceeds all VDE 0250-813 requirements.

GOST-R / GOST-K / GOST-B: Certification by the Russian Federal Agency on Technical Regulating and Metrology (Rosstandart), ensuring the cable meets Russian Federation, Kazakh Republic, and Belarus technical safety standards. These certifications are mandatory for mining equipment operating in these jurisdictions.

DIN EN 60228 / IEC 60228 / VDE 0295: Conductor material and stranding standards, ensuring conductor purity, mechanical properties, and corrosion resistance.

DIN EN 60332-1-2 / IEC 60332-1-2: Flame retardancy testing standard, confirming that the cable’s outer sheath does not propagate flame in the event of electrical fault or fire.

Oil / Ozone / UV Resistance: The cable material is validated for resistance to mineral oil contamination (common in mining), ozone exposure (from arc faults), and UV radiation (from Arctic sunlight and high-altitude UV penetration).

References & Further Documentation

1. Anhui FeiChun Special Cable Co., Ltd., “TENAX-SAS (N)TSCGEWOEU-LED 14/25 kV Self-Powered LED Illuminated MV Trailing Cable — Technical Data Sheet FC-TDS-TSCGEWOEU25-LED-2026-01BC4B8B, Rev. A1,” Hefei, March 2026. Available from [email protected]
2. 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.
3. International Electrotechnical Commission (IEC), “IEC 60502-2: Power cables with extruded insulation and their accessories for rated voltages from 6 kV (Um = 7.2 kV) up to and including 30 kV (Um = 36 kV),” Geneva, 2014.
4. Federal Agency on Technical Regulating and Metrology (Rosstandart), “GOST R 55025: Electric cables and wires for open-cast mines and quarries,” Moscow, 2012.
5. FeiChun Proprietary Testing Documentation: “Cold-Start Performance Validation of FC-EMH™ X-Variant Regulators at −50 °C & −60 °C Wind-Chill: Arctic Research Testing Report,” Russian Arctic Research & Technology Center, Norilsk, 2025. Available from [email protected]
6. American Society for Testing and Materials (ASTM) D2671, “Standard Test Method for Tensile Properties of Plastic Films and Sheets,” 2019.
7. International Organization for Standardization (ISO) 1419, “Rubber — Determination of low temperature crystallization,” 2019.