What is PROTOLON(M) R-(N)TSCGEWOEU FO 6 kV – 35 kV Medium Voltage Reeling Cable with Integrated Fiber-Optics?
A Comprehensive Technical Guide by Anhui Feichun Special Cable Co., Ltd (安徽飞纯特种电缆有限公司)
Introduction to PROTOLON(M) R-(N)TSCGEWOEU FO Cable
The PROTOLON(M) R-(N)TSCGEWOEU FO represents a sophisticated engineering solution that combines medium voltage power transmission with integrated fiber-optic communication capabilities in a single cable design. This innovative reeling cable is specifically engineered for demanding industrial applications where large mobile equipment requires simultaneous electrical power supply and high-speed data transmission under extreme mechanical stress conditions. The cable is manufactured according to the stringent requirements of DIN VDE 0250-813 standard, which is recognized globally as the definitive specification for flexible trailing cables used in heavy industrial applications.
As noted by industry experts, flexible medium voltage cables with integrated fiber optics enable the combined transmission of energy and data for applications under high mechanical stresses, including high travel speeds, dynamic tensile loads, and multiple directional changes. This dual-functionality eliminates the need for separate power and communication cables, thereby reducing installation complexity, minimizing cable management challenges, and improving overall system reliability in harsh operating environments such as open-cast mining operations.
Primary Applications and Purpose
The PROTOLON(M) R-(N)TSCGEWOEU FO cable is specifically designed for connection of large-scale material handling machinery in open-cast mining operations. The primary applications include powering and providing data communication for excavators, bucket-wheel excavators, mobile dumpers, spreaders, mobile crushers, and stacker-reclaimers. These applications demand cables that can withstand continuous mechanical stress while maintaining reliable electrical and optical performance.
Key Application Environments:
This cable excels in environments requiring motorized reeling systems with mono-spiral reels and cylindrical level-wind reelers. The design accommodates high travel speeds exceeding 240 meters per minute, dynamic tensile loads during acceleration, multiple changes of direction across different planes, and continuous torsional stresses. For more information on reeling cable applications in mining environments, visit reelingcable.com and explore specialized mining cable solutions at miningcable.cl.
The integration of fiber-optic elements enables real-time monitoring of equipment performance, remote diagnostics, process automation data transmission, and video surveillance capabilities. This convergence of power and data infrastructure supports modern Industry 4.0 initiatives in mining operations, facilitating predictive maintenance strategies and optimizing operational efficiency. Resources from amplexmining.com.au demonstrate how advanced cable systems contribute to safer and more efficient mining operations.
Technical Characteristics and Design Features
Conductor Design and Electrical Properties
The cable employs bare electrolytic copper conductors with very fine stranding classified as Class FS (Flexible Stranding) according to DIN VDE 0295. This ultra-flexible conductor construction provides exceptional bending characteristics essential for reeling applications. The conductor temperature ratings are carefully specified: maximum permissible operating temperature at conductor is 90°C, while short circuit conditions permit temperatures up to 250°C for brief durations. The maximum tensile load on the conductor is rated at 20 N/mm² during normal operation, with allowances up to 30 N/mm² during acceleration phases, substantially exceeding the standard 15 N/mm² specified in DIN VDE 0298 Part 3.
Insulation System and Field Control
The insulation system utilizes a high-grade lead-free special compound based on HEPR (Hard Ethylene Propylene Rubber) technology, surpassing the performance characteristics of standard 3GI3 compounds as specified in DIN VDE 0207-21. This advanced insulation material delivers superior mechanical properties, enhanced electrical characteristics, and improved resistance to environmental stresses including ozone, ultraviolet radiation, and moisture exposure.
The electrical field control system incorporates both inner and outer layers of semi-conductive rubber compound. The inner semiconductive layer utilizes EPR (Ethylene Propylene Rubber), while the outer layer employs modified NBR (Nitrile Butadiene Rubber) that is cold-strippable, significantly simplifying field termination procedures. This “Easy Strip” design reduces installation time and minimizes the risk of improper termination, which is particularly valuable in remote mining locations.
| Electrical Parameter | Specification | Standard Reference |
|---|---|---|
| Voltage Rating | 6 kV to 35 kV (Uo/U: 3.6/6 kV – 20/35 kV) | DIN VDE 0250-813 |
| Max. Conductor Temperature | 90°C (continuous operation) | DIN VDE 0298-4 |
| Short Circuit Temperature | 250°C (transient) | DIN VDE 0298-4 |
| Max. Tensile Load | 20 N/mm² (30 N/mm² during acceleration) | DIN VDE 0298 Part 3 |
| Ambient Temperature (Fixed Installation) | -50°C to +80°C | DIN VDE 0298-4 |
| Ambient Temperature (Flexible Operation) | -35°C to +80°C | DIN VDE 0298-4 |
Fiber-Optic Integration Specifications
The integrated fiber-optic system represents a critical component of the cable’s design, enabling high-bandwidth data transmission alongside power delivery. The optical fibers are housed in loose tube construction with filling compound, utilizing ETFE (Ethylene Tetrafluoroethylene) as the basic material for the tube with 7YI 1 compound in natural color. The arrangement consists of six tubes laid up around a central support element, with up to four fibers in each tube, allowing configurations up to 24 fibers total.
| Fiber Type | Parameter | Specification |
|---|---|---|
| G50/125 Multimode | Attenuation at 850 nm | <2.8 dB/km |
| Attenuation at 1310 nm | <0.8 dB/km | |
| Bandwidth at 850 nm | >400 MHz | |
| Bandwidth at 1300 nm | >1200 MHz | |
| Numerical Aperture | 0.20 ± 0.02 | |
| G62.5/125 Multimode | Attenuation at 850 nm | <3.3 dB/km |
| Attenuation at 1310 nm | <0.9 dB/km | |
| Bandwidth at 850 nm | >400 MHz | |
| Bandwidth at 1300 nm | >600 MHz | |
| Numerical Aperture | 0.275 ± 0.02 | |
| E9/125 Single-mode | Attenuation at 1310 nm | <0.4 dB/km |
| Attenuation at 1550 nm | <0.3 dB/km | |
| Numerical Aperture | 0.14 ± 0.02 | |
| Chromatic Dispersion at 1310 nm | <3.5 ps/nm·km | |
| Chromatic Dispersion at 1550 nm | <18 ps/nm·km |
All fibers feature an inner core diameter of 9 μm (single-mode), 50 μm, or 62.5 μm (multimode), with diameter over cladding of 125 μm and diameter over coating of 250 μm. The fibers and buffering tubes are color-coded for identification of fiber type, facilitating proper termination and maintenance procedures. Industry standards recommend that fiber-optic termination be performed by specialized technicians with appropriate tools and training to ensure optimal performance.
Material Structure and Construction Layers
Core Configuration and Identification
The cable employs a three-core design with a split earth conductor configuration. The earth conductor is divided into segments positioned in the interstices between the power cores, with the fiber-optic element occupying the remaining interstice. This arrangement optimizes the cable’s mechanical balance while maintaining compact overall dimensions. The cores feature natural colored insulation with black semi-conductive rubber layers and white numerical identification (cores 1-3), enabling clear phase identification during installation and maintenance.
Sheath System and Mechanical Protection
The cable incorporates a sophisticated multi-layer sheath system designed to provide exceptional mechanical protection and environmental resistance. The inner sheath utilizes EPR (Ethylene Propylene Rubber) compound type 5GM3, serving multiple functions including electrical isolation, moisture barrier, and mechanical cushioning. This inner sheath creates a foundation for the subsequent protective layers.
A critical feature is the torsion protection layer consisting of a braid of polyester threads in a vulcanized bond positioned between the inner and outer sheaths. This anti-torsion braid dramatically enhances the cable’s resistance to twisting forces encountered during reeling operations, preventing internal structural damage and extending service life. According to testing protocols outlined in DIN EN 60811-404 and DIN VDE 0473-811-404, the cable demonstrates superior performance under torsional stress conditions compared to cables without this protective feature.
The outer sheath employs a high-grade chloroprene compound designated as CR/PCP, exceeding the performance characteristics of standard 5GM5 compounds as specified in DIN VDE 0207. This outer sheath provides outstanding resistance to abrasion, tearing, ozone, ultraviolet radiation, oils, chemicals, and flame propagation. The standard color is red, though alternative colors are available upon customer request to facilitate identification in complex cable installations. For specialized crane applications, additional information is available at cranecable.com.
| Construction Layer | Material/Compound | Primary Function |
|---|---|---|
| Conductor | Bare electrolytic copper, Class FS | Current conduction |
| Insulation | HEPR special compound (better than 3GI3) | Electrical insulation, mechanical strength |
| Inner Semiconductive Layer | EPR compound | Electric field control |
| Outer Semiconductive Layer | Modified NBR (cold strippable) | Electric field control, easy termination |
| Fiber Optic Covering | ETFE loose tube with 7YI 1 compound | Fiber protection, flexibility |
| Inner Sheath | EPR compound type 5GM3 | Moisture barrier, mechanical cushioning |
| Torsion Protection | Polyester braid (vulcanized bond) | Torsional stress resistance |
| Outer Sheath | CR/PCP chloroprene (better than 5GM5) | Environmental protection, abrasion resistance |
Compliance with International Standards
The PROTOLON(M) R-(N)TSCGEWOEU FO cable is designed and manufactured based on DIN VDE 0250-813, which is the German national standard for trailing cables used in power installations. As noted by cable industry authorities, DIN VDE 0250-813 is recognized globally as the ultimate standard for tough rubber sheathed flexible reeling cables, particularly because Germany is the only country to have issued special design regulations specifically for flexible electrical cables covering cranes and material handling equipment.
The cable has obtained Fire Certificate approval from the Russian Federation (GOST-R/-K/-B), demonstrating its compliance with stringent fire safety requirements for use in hazardous industrial environments. This certification is particularly important for mining applications where fire prevention and containment are critical safety considerations.
Key Standards and Certifications:
- DIN VDE 0250-813: Primary design standard for trailing cables, covering voltage ratings from 0.6/1 kV to 20/35 kV
- DIN VDE 0207: Specifications for rubber compounds used in cable insulation and sheathing materials
- DIN VDE 0295: Conductor stranding classifications and requirements
- DIN VDE 0298: Current carrying capacity calculations and installation parameters (Parts 3 and 4)
- DIN EN 60811-404: Test methods for cable materials under mechanical stress
- DIN VDE 0473-811-404: Additional verification testing protocols
- GOST-R/-K/-B: Russian Federation Fire Safety Certification
The cable undergoes comprehensive testing including reversed bending tests, torsional stress tests, and flame propagation tests to verify compliance with all applicable standards. The manufacturing processes at Anhui Feichun Special Cable Co., Ltd. adhere to ISO 9001 quality management systems, ensuring consistent product quality and traceability throughout production.
Safety Thresholds and Operating Parameters
Understanding and adhering to the specified safety thresholds is essential for ensuring reliable operation and preventing premature cable failure. The cable is designed with specific operating envelopes that must be respected during installation and use.
Bending Radius and Mechanical Limits
The minimum bending radius must be calculated according to DIN VDE 0298 Part 3, typically specified as a multiple of the cable’s outer diameter. For S-type directional changes (reversing bends), the minimum distance between bend points must be at least 20 times the cable diameter (20 × D) to prevent excessive stress concentration. These parameters are critical for proper reel design and cable routing.
Travel Speed and Dynamic Loading
For gantry reeling operations, the cable supports unrestricted travel speeds. However, for speeds exceeding 240 meters per minute, consultation with the cable manufacturer or technical specialists is recommended to verify that the specific installation conditions remain within acceptable parameters. The cable’s design accommodates dynamic tensile loads during acceleration, with conductor stress limits up to 30 N/mm² permitted during these transient conditions.
| Safety Parameter | Threshold Value | Consequence of Exceeding |
|---|---|---|
| Maximum Continuous Conductor Temperature | 90°C | Insulation degradation, reduced service life |
| Maximum Short Circuit Temperature | 250°C (brief duration) | Permanent insulation damage, conductor annealing |
| Minimum Installation Temperature | -50°C (fixed), -35°C (flexible) | Material cracking, reduced flexibility |
| Maximum Tensile Load (Normal Operation) | 20 N/mm² | Conductor elongation, connection failure |
| Maximum Tensile Load (Acceleration) | 30 N/mm² | Permanent conductor deformation |
| Minimum Bending Radius | Per DIN VDE 0298-3 | Insulation crushing, fiber damage |
| S-Type Bend Spacing | ≥ 20 × Cable Diameter | Accelerated fatigue, premature failure |
Installation Precautions and Best Practices
General Installation Guidelines
Proper installation of the PROTOLON(M) R-(N)TSCGEWOEU FO cable is crucial for achieving optimal performance and service life. The cable should be installed by qualified professionals with experience in medium voltage cable systems and fiber-optic termination. All work must comply with applicable electrical codes, safety regulations, and manufacturer specifications.
Prior to installation, conduct a thorough inspection of the cable for any signs of damage sustained during transportation or storage. Examine the outer sheath for cuts, abrasions, or deformations. Verify that the cable has been stored in environmental conditions that comply with the manufacturer’s recommendations, typically between -35°C and +80°C for flexible operation scenarios.
Reel System Compatibility
The cable is specifically designed for use with motorized mono-spiral reels and cylindrical level-wind reelers. Ensure that the reel drum diameter provides adequate bending radius according to DIN VDE 0298 Part 3. The reel design must prevent cable crushing, excessive side pull, and improper spooling that could induce torsional stress. Proper fleet angle maintenance is essential to prevent premature wear.
Fiber-Optic Termination Requirements
Termination of the integrated fiber-optic elements requires specialized skills, precision tools, and controlled environmental conditions. The loose tube design with filling compound necessitates careful cleaning procedures to remove the compound without damaging the delicate optical fibers. Industry best practices recommend that fiber-optic termination be performed in a clean, dry environment by technicians with appropriate certification and experience.
Critical Installation Precautions:
- Never exceed the specified minimum bending radius during installation or operation
- Avoid pulling the cable over sharp edges or rough surfaces that could damage the outer sheath
- Do not apply tensile loads exceeding 20 N/mm² during cable pulling operations
- Ensure proper grounding of the split earth conductor segments at both cable ends
- Protect cable ends from moisture ingress during installation using appropriate sealing methods
- Use only approved termination accessories designed for medium voltage applications
- Verify proper phase rotation and connection polarity before energizing the cable
- Conduct high-potential (hi-pot) testing according to applicable standards before placing into service
- Maintain detailed installation documentation including termination records and test results
Environmental Considerations
While the cable is designed for outdoor use and exhibits excellent resistance to ozone, UV radiation, and moisture, proper cable management practices enhance reliability. Provide adequate drainage to prevent water accumulation at low points in the cable route. In applications involving exposure to chemicals or petroleum products, verify compatibility with the CR/PCP outer sheath material. For specialized mining applications, comprehensive resources are available at feichuncable.com.
Common Problems and Troubleshooting
Mechanical Damage and Wear
The most common issue encountered with reeling cables is mechanical damage to the outer sheath caused by abrasion, impact, or improper handling. Signs of mechanical wear include visible scoring on the sheath surface, localized flattening, or exposure of the underlying protective layers. Regular visual inspections should be conducted during scheduled maintenance intervals to identify early signs of wear before they compromise the cable’s integrity.
Premature wear often indicates improper installation parameters, such as inadequate bending radius, excessive fleet angle on the reel, or misalignment of cable guides. Investigate and correct the root cause rather than simply replacing the damaged cable section. According to industry research on flexible cable applications, proper installation and maintenance can extend cable service life by 300-500% compared to poorly managed installations.
Electrical Insulation Degradation
Insulation resistance degradation typically manifests as gradually increasing leakage current or intermittent ground faults. This condition may result from moisture ingress through damaged sheath areas, thermal aging from sustained operation at elevated temperatures, or chemical attack from incompatible substances. Periodic insulation resistance testing using a megohmmeter (typically 5 kV DC test voltage for 6 kV cables) provides early warning of insulation deterioration.
If insulation resistance falls below acceptable thresholds (typically greater than 100 MΩ per kilometer at 20°C), investigate potential causes including water penetration at termination points, damage to the outer sheath, or excessive operating temperatures. Note that cold temperatures can temporarily increase insulation resistance readings, while elevated temperatures decrease resistance values—temperature correction factors should be applied when interpreting test results.
Fiber-Optic Performance Issues
Optical signal degradation manifests as increased bit error rates, reduced signal strength, or complete communication loss. Common causes include excessive bending beyond the fiber’s minimum radius (typically 20-30 times the cable outer diameter under static conditions), mechanical stress causing microbending losses, connector contamination, or physical fiber breakage.
Systematic troubleshooting should begin with optical time-domain reflectometer (OTDR) testing to locate the position of signal loss or reflection anomalies. Clean and inspect all connectors using appropriate fiber-optic cleaning procedures. Verify that installation parameters comply with specified bending radius requirements. If fiber damage is localized, splice repair may be possible; however, extensive fiber degradation typically necessitates cable replacement.
Connection and Termination Failures
Poor termination practices account for a significant percentage of cable system failures. Common termination issues include improper stress cone installation, inadequate electric field control, moisture ingress at the termination point, and mechanical stress at the cable entry. These problems can lead to partial discharge activity, tracking, and eventual insulation breakdown.
All terminations should be performed by qualified personnel using approved accessories and following manufacturer procedures. High-quality terminations will exhibit minimal partial discharge activity when tested with appropriate instruments. Regular thermographic surveys can detect developing hot spots at connections before they progress to failure.
| Problem Symptom | Likely Causes | Diagnostic Approach | Solution |
|---|---|---|---|
| Outer sheath abrasion | Improper reel alignment, sharp edges, excessive fleet angle | Visual inspection, fleet angle measurement | Correct installation parameters, install cable guards |
| Ground faults | Moisture ingress, insulation damage, termination failure | Insulation resistance test, hi-pot test, visual inspection | Identify entry point, repair sheath, re-terminate |
| Overheating | Overloading, poor connections, inadequate ventilation | Thermography, load measurement, contact resistance test | Verify loading, improve connections, enhance cooling |
| Fiber signal loss | Excessive bending, connector contamination, fiber breakage | OTDR test, visual inspection, connector inspection | Correct bending radius, clean connectors, splice or replace |
| Premature failure | Exceeding design parameters, improper installation | Installation review, operational parameter verification | Redesign installation, verify all parameters |
| Torsional damage | Improper reel type, insufficient torsion protection | Visual inspection of internal construction | Use appropriate reel system, verify cable specification |
Preventive Maintenance Program
Implementing a comprehensive preventive maintenance program significantly reduces unexpected cable failures and extends service life. The program should include regular visual inspections (monthly for critical applications), periodic electrical testing including insulation resistance and ground continuity (quarterly or semi-annually), thermographic surveys to detect developing hot spots (annually), and fiber-optic performance testing using OTDR and power meters (annually or as needed).
Maintain detailed maintenance records documenting inspection findings, test results, repairs performed, and operational parameters. This historical data enables trend analysis that can predict potential failures before they occur, facilitating planned maintenance during scheduled downtime rather than emergency repairs during production periods.
Advantages of PROTOLON(M) Technology
The PROTOLON(M) R-(N)TSCGEWOEU FO cable offers numerous advantages over conventional separate power and communication cable installations. The integrated design reduces installation complexity and time by eliminating the need for separate cable trays or conduit systems. This consolidation also minimizes cable management challenges on mobile equipment, reducing the potential for cable entanglement or damage.
The advanced HEPR insulation compound provides superior electrical performance compared to traditional materials, including lower dielectric losses, higher insulation resistance, and improved resistance to partial discharge activity. The cold-strippable outer semiconductive layer simplifies field termination, reducing labor costs and the risk of improper installation that could compromise system reliability.
The torsion protection braid represents a critical design feature that distinguishes this cable from conventional flexible cables. This protective layer absorbs torsional stresses that would otherwise be transmitted to the conductor and insulation layers, preventing premature failure in demanding reeling applications. Independent testing has demonstrated that cables with proper torsion protection can achieve service lives 2-3 times longer than cables without this feature when used in equivalent applications.
The high-grade CR/PCP outer sheath provides outstanding environmental resistance, maintaining flexibility and mechanical properties across a wide temperature range while resisting ozone, UV radiation, oils, and chemicals commonly encountered in mining environments. This durability translates to reduced maintenance requirements and lower total cost of ownership over the cable’s operational life.
Technical Support and Specifications
Anhui Feichun Special Cable Co., Ltd. (安徽飞纯特种电缆有限公司) provides comprehensive technical support for the PROTOLON(M) cable product line, including application engineering assistance, custom design services, installation guidance, and after-sales technical consultation. The company’s engineering team can assist with cable selection, reel system design, termination planning, and troubleshooting support.
Custom configurations are available to meet specific application requirements, including alternative voltage ratings, conductor sizes, fiber-optic configurations, sheath colors, and specialized certifications. For projects with unique environmental conditions or performance requirements, the engineering team can evaluate feasibility and develop tailored solutions.
Standard Cable Configurations:
- Voltage Ratings: 3.6/6 kV, 6/10 kV, 8.7/15 kV, 12/20 kV, 18/30 kV, 20/35 kV
- Conductor Sizes: 16 mm² to 240 mm² (other sizes available on request)
- Number of Cores: Three-core with split earth conductor
- Fiber Configurations: 4, 8, 12, 16, 20, or 24 fibers
- Fiber Types: G50/125, G62.5/125 multimode; E9/125 single-mode
- Sheath Colors: Red (standard), other colors available on request
- Reel Types: Compatible with mono-spiral and cylindrical level-wind reels
Detailed technical data sheets, installation manuals, and application notes are available from Anhui Feichun Special Cable Co., Ltd. These documents provide comprehensive information on cable specifications, installation procedures, testing protocols, and maintenance recommendations specific to each cable configuration.
Quality Assurance and Manufacturing Excellence
Anhui Feichun Special Cable Co., Ltd. maintains rigorous quality control throughout the manufacturing process, from raw material inspection through final product testing. The company’s production facilities utilize state-of-the-art extrusion and curing equipment, automated testing systems, and comprehensive quality management procedures compliant with ISO 9001 international standards.
Each cable undergoes extensive testing before shipment, including conductor resistance verification, insulation resistance testing at elevated voltage, high-potential (hi-pot) testing to verify dielectric strength, partial discharge testing to ensure insulation quality, outer sheath thickness and concentricity measurements, fiber-optic attenuation and bandwidth testing, and mechanical properties verification of insulation and sheath materials.
Traceability systems ensure that all materials, processes, and test results are documented and retained, enabling investigation of any field issues and facilitating continuous improvement initiatives. The company’s commitment to quality has earned recognition from major mining companies and equipment manufacturers worldwide.
Contact Anhui Feichun Special Cable Co., Ltd.
For technical inquiries, custom cable solutions, or product orders, please contact our experienced team:
Visit our website for additional product information, technical resources, and case studies: www.feichuncable.com
Conclusion
The PROTOLON(M) R-(N)TSCGEWOEU FO cable represents an advanced engineering solution that addresses the demanding requirements of modern mining and heavy industrial applications. By integrating medium voltage power transmission and fiber-optic communication capabilities in a single robust package, this cable simplifies installation, reduces system complexity, and enhances reliability in harsh operating environments.
The cable’s sophisticated design incorporates premium materials, advanced construction techniques, and proven protective features including ultra-flexible Class FS conductors, high-performance HEPR insulation, integrated fiber-optic elements with loose tube protection, anti-torsion braid for enhanced durability, and rugged CR/PCP outer sheath for environmental resistance. These features combine to deliver exceptional performance, longevity, and value in applications ranging from excavators and mobile crushers to material handling systems in open-cast mining operations.
Compliance with DIN VDE 0250-813 and other international standards ensures that the cable meets stringent requirements for electrical safety, mechanical performance, and operational reliability. When properly specified, installed, and maintained, the PROTOLON(M) cable provides many years of trouble-free service, supporting the productivity and safety objectives of modern mining operations.
For expert guidance on cable selection, custom design solutions, or technical support, the engineering team at Anhui Feichun Special Cable Co., Ltd. stands ready to assist with your most challenging cable application requirements. Contact us today to discover how PROTOLON(M) technology can enhance your operational efficiency and reliability.
