What is R-(N)TSCGEWOEU Protolon (M)-R Cable W-9 High Voltage Round Reeling Cable?
⚡ High Voltage Warning
This is a MEDIUM/HIGH VOLTAGE cable system rated from 3.6/6 kV up to 12/20 kV. Installation, termination, and maintenance must only be performed by qualified electrical personnel trained in high voltage systems. Improper handling can result in severe injury or death.
The R-(N)TSCGEWOEU cable, marketed under the Protolon (M)-R and W-9 brand designations, represents the pinnacle of medium to high voltage reeling cable technology for extreme industrial applications. This sophisticated cable system is specifically engineered for fast-moving container cranes, heavy mining equipment, stackers, reclaimers, and ship unloaders where conventional medium voltage cables would fail.
Available in four voltage ratings:
Higher voltage grades available upon request
Table of Contents
- 1. Purpose and Primary Applications
- 2. Key Characteristics and Performance Features
- 3. Material Structure and Construction
- 4. Compliance with International Standards
- 5. Safety Thresholds and Operating Parameters
- 6. Precautions for Use and Installation
- 7. Common Problems and Troubleshooting
- 8. Cable Selection and Specification Guide
- 9. Fiber Optic Integration (FO Variants)
1. Purpose and Primary Applications
The R-(N)TSCGEWOEU cable series is designed for medium voltage power transmission in applications subjected to extreme mechanical stresses that would destroy standard MV cables. The cable excels in environments requiring high reliability, continuous flexing, and resistance to harsh conditions.
Primary Application Profile
Motorized Cable Reels – Main Application
The cable is primarily designed for motorized cable reel systems where:
- Small to medium dynamic loads are expected during reel operation
- The reeling duty cycle is in the low to medium range
- A reliable, durable, yet cost-effective MV cable solution is required
- Operation through one diversion roller assembly is needed
- Operating temperatures do not exceed 60°C in flexing applications
- Up to 12 optical fibers are required for data transmission (FO variants)
Typical Industrial Applications
2. Key Characteristics and Performance Features
High Torsional Rigidity
Reinforced textile braid vulcanized between inner and outer sheaths in a unique “sandwich” structure provides exceptional resistance to twisting forces during continuous reeling operations.
Easy Layer Separation
Special EPR-based compound formulation allows easy separation of individual insulation layers, simplifying termination and field repair procedures.
Compact High-Voltage Design
Minimized cable diameter and weight despite high voltage insulation requirements enable smaller reel dimensions – critical in space-constrained port and crane installations.
Integrated Data Transmission
Standard 12 optical fiber capacity in FO variants provides high-speed data transfer alongside power distribution, reducing cable quantity and complexity.
Superior Mechanical Stability
Triple-layer simultaneous extrusion of core insulation sheathings ensures uniform thickness, optimal adhesion, and maximum mechanical integrity under dynamic stress.
Very High Tensile Strength
Compact, ideally interconnected reinforcements using high-quality materials provide 20 N/mm² continuous tensile capacity (up to 30 N/mm² during acceleration).
Excellent Resilience
Particularly flexible short-lay FS (super-flexible) conductors exceed Category 5 flexibility standards, providing outstanding recovery from mechanical stress and bending fatigue resistance.
PROTOFIRM Sandwich Sheath
Innovative dual-layer inner sheath system with anti-torsion braid creates exceptional resistance to mechanical damage and environmental exposure.
Mechanical Performance Specifications
| Parameter | Specification |
|---|---|
| Maximum Travel Speed | Up to 80 m/min (higher speeds available on request) |
| Minimum Bending Radius – Static Installation | 6 × cable outer diameter (∅) |
| Minimum Bending Radius – On Reel | 12 × cable outer diameter (∅) |
| Minimum Bending Radius – Track Curve | 15 × cable outer diameter (∅) |
| Minimum Bending Radius – S-Track Curve | 20 × cable outer diameter (∅) |
| Torsional Stress Capacity | ± 100°/m (per meter length) |
| Tensile Load-Bearing Capacity (Continuous) | 20 N/mm² |
| Tensile Load-Bearing Capacity (Acceleration) | Up to 30 N/mm² |
Environmental & Chemical Resistance
- Flame Retardant: Self-extinguishing properties according to DIN VDE 0482 Part 265-2-1 and IEC 60332-1
- CFC-Free: Environmentally compliant manufacturing process
- Oil-Resistant: Polychloroprene (PCP) outer sheath provides excellent resistance to industrial oils and lubricants
- UV-Resistant: Maintains electrical and mechanical properties under direct sunlight
- LBS-Free / Silicone-Free: Compatible with sensitive manufacturing environments
- Moisture-Resistant: Performs reliably in humid and wet conditions
- Ozone-Resistant: Long-term stability in oxidizing environments
- Unlimited Resistance to Atmospheric Corrosion
3. Material Structure and Construction
Layer-by-Layer Construction (Center to Outer)
1. Conductor Core
Material: Soft electrolytic copper, tin-plated
Class: FS (Fein Stranded) – More flexible than Category 5 per DIN VDE 0295
Configuration: Very finely stranded for maximum flexibility and resilience
Stranding: Short-lay layered construction for optimal flexibility
2. Inner Semiconductive Layer
Material: Semiconducting EPR rubber compound (per DIN VDE 0207 Part 20)
Function: Electrical field control, ensures uniform electric field distribution across insulation
Properties: Prevents electrical stress concentration at conductor surface
3. Primary Insulation
Material: PROTOLON HS – High-grade EPR (Ethylene Propylene Rubber)
Quality: Minimum 3GI3 grade per DIN VDE 0207
Properties: Improved mechanical and electrical characteristics, excellent dielectric strength
Extrusion: Simultaneous triple-layer extrusion ensures optimal layer adhesion
4. Outer Semiconductive Layer
Material: Modified NBR (Nitrile Butadiene Rubber) semiconductive compound
Special Feature: “Easy Strip” design – can be stripped cold without tools
Function: Electrical field control, dramatically simplifies termination preparation
Color: Black for visual distinction
5. Core Identification
Insulation Color: Natural colored EPR
Semiconductive Layer: Black
Core Arrangement: Three-core design with earth conductor split into 3 parts positioned in interstices (standard) or halved for FO variants
6. Inner Sheath (PROTOFIRM System)
Material: Special red EPR compound, quality 5GM3 minimum
Function: Serves as water barrier and mechanical protection
Color: Red for identification
Properties: Excellent mechanical properties, chemical resistance
7. Anti-Torsion Braid
Material: Reinforced polyester textile braid
Construction: Vulcanized between inner and outer sheaths in sandwich structure
Function: Provides maximum protection against torsional forces during reeling
Integration: Permanently bonded to sheaths for unified mechanical structure
8. Outer Sheath
Material: Abrasion-resistant PCP (Polychloroprene) based compound
Quality: Minimum 5GM5 per DIN VDE 0207
Properties: Tear-proof, oil-resistant, flame retardant, excellent resilience
Color: Black (standard)
Design Code Breakdown: R-(N)TSCGEWOEU
| Code Element | Meaning |
|---|---|
| R | Cable suitable for use on reels (Reeling cable) |
| (N) | Adapted to standard (normalized design) |
| TS | Heavy-duty cable with special insulation |
| C | Conducting non-metallic covering surrounding the insulations |
| GE | Gemeinsamer Erdleiter (Combined ground conductor) |
| W | Resistant to atmospheric corrosion (Weather-resistant) |
| O | Oil-resistant outer sheath |
| E | Single-wire armoring or earthing layer |
| U | Outer sheath of low flammability per DIN VDE 0472 Part 804 |
4. Compliance with International Standards
Primary Standards Compliance
- DIN VDE 0250-813 – Cables, wires and flexible cords for power installation; trailing cables for medium voltage (VDE)
- HD 620 S2 – Distribution cables of rated voltage 0.6/1.0 kV (European harmonization document)
- DIN VDE 0295 – Conductors of insulated cables (FS super-flexible conductor classification)
- DIN VDE 0207, Part 20 – Insulating and sheathing materials for cables and flexible cords – EPR insulation compounds
- DIN VDE 0298, Part 3 – Application of cables and cords in power installations – Installation of cables
- DIN VDE 0298, Part 4 – Current-carrying capacity calculation methods
- DIN VDE 0482, Part 265-2-1 – Flame retardancy testing procedures
- IEC 60332-1 – Tests on electric cables under fire conditions – Vertical flame propagation test (IEC)
- DIN VDE 0472, Part 804 – Testing of cables, wires and flexible cords – Burning behavior
- DIN VDE 0168 – Cable systems for mining and similar applications (where applicable)
- GOST-R – Russian certification (available)
These comprehensive standards ensure the cable meets stringent requirements for high voltage electrical safety, mechanical durability, fire resistance, and environmental protection in demanding industrial applications.
5. Safety Thresholds and Operating Parameters
Electrical Safety Parameters by Voltage Rating
| Parameter | 3.6/6 kV | 6/10 kV | 8.7/15 kV | 12/20 kV |
|---|---|---|---|---|
| Rated Voltage (Uo/U) AC | 3.6/6.0 kV | 6.0/10.0 kV | 8.7/15.0 kV | 12.0/20.0 kV |
| Max. AC Operating Voltage | 4.2/7.2 kV | 7.0/12.0 kV | 10.2/18.0 kV | 14.0/24.0 kV |
| Max. DC Operating Voltage | 5.4/10.8 kV | 9.0/18.0 kV | 13.0/26.0 kV | 18.0/36.0 kV |
| AC Test Voltage | According to DIN VDE 0250-813 | |||
Thermal Operating Ranges
| Operating Condition | Temperature Range |
|---|---|
| Flexing (Dynamic) Applications | -25°C to +60°C |
| Fixed (Static) Installation | -40°C to +80°C |
| Maximum Conductor Operating Temperature | 90°C (continuous) |
| Short-Circuit Temperature (Maximum Transient) | 250°C |
⚠ Critical Temperature Limitations
For flexing applications on cable reels, the maximum ambient temperature is LIMITED to +60°C. This is lower than the fixed installation limit due to the additional thermal stress from continuous flexing and potential heat buildup on wound cables. Exceeding this limit will cause premature insulation degradation and failure.
Current Carrying Capacity (Ampacity) Examples
3.6/6 kV Rating
| Configuration | Cross-Section | Outer Diameter | Weight | Ampacity (IB) | Tensile Load |
|---|---|---|---|---|---|
| 3 x 25 + 3G25/3 | 25 mm² | 36.3 – 39.3 mm | 2,215 kg/km | 108.8 A | 1,500 N |
| 3 x 50 + 3G25/3 | 50 mm² | 43.8 – 46.8 mm | 3,439 kg/km | 161.6 A | 3,000 N |
| 3 x 95 + 3G50/3 | 95 mm² | 52.7 – 56.7 mm | 5,635 kg/km | 240.8 A | 5,700 N |
| 3 x 150 + 3G70/3 | 150 mm² | 61.9 – 65.9 mm | 8,180 kg/km | 323.2 A | 9,000 N |
12/20 kV Rating (Highest Voltage Grade)
| Configuration | Cross-Section | Outer Diameter | Weight | Ampacity (IB) | Tensile Load |
|---|---|---|---|---|---|
| 3 x 25 + 3G25/3 | 25 mm² | 45.1 – 48.1 mm | 2,982 kg/km | 111.2 A | 1,500 N |
| 3 x 50 + 3G25/3 | 50 mm² | 52.5 – 56.5 mm | 4,399 kg/km | 172.8 A | 3,000 N |
| 3 x 95 + 3G50/3 | 95 mm² | 61.9 – 65.9 mm | 6,783 kg/km | 255.2 A | 5,700 N |
| 3 x 150 + 3G70/3 | 150 mm² | 69.7 – 73.7 mm | 9,323 kg/km | 342.4 A | 9,000 N |
⚠ Ampacity Calculation Conditions
The ampacity values are based on:
- Ambient temperature: 30°C
- Monospiral reel coil configuration
- 100% duty cycle (continuous operation)
- Single cable on reel (no bundling)
Actual current carrying capacity can vary significantly based on:
- Higher ambient temperatures (reduce ampacity)
- Multiple layers wound on reel (heat dissipation constraints)
- Duty cycle and load profile
- Ventilation conditions
- Method of installation
Always consult manufacturer’s technical documentation or use DIN VDE 0298 Part 4 calculations for specific conditions.
6. Precautions for Use and Installation
⚡ High Voltage Safety – Critical Requirements
- Qualified Personnel Only: All installation, termination, testing, and maintenance must be performed by electricians qualified and certified for medium/high voltage work.
- De-Energization Procedures: Always follow proper lockout/tagout procedures. Verify de-energization with appropriate voltage detectors rated for the system voltage.
- Grounding: Temporarily ground all conductors during installation and maintenance to protect against induced voltages and capacitive discharge.
- Insulation Testing: Perform high-voltage insulation resistance testing (megger testing) before energization and after any maintenance.
- Clearances: Maintain proper electrical clearances per local electrical codes and standards.
- Arc Flash Hazard: Assess arc flash hazards and use appropriate PPE when working on or near energized equipment.
Installation Guidelines
Mechanical Installation Requirements
- Minimum Bending Radii: Strictly adhere to specified bending radii:
- 12× diameter for normal reeling operations
- 15× diameter at track curves
- 20× diameter at S-track curves
- 6× diameter for fixed installation (no flexing)
- Tensile Load Management: Never exceed 20 N/mm² during continuous operation or 30 N/mm² during acceleration phases.
- Travel Speed Limitations: Maximum 80 m/min for standard applications. Higher speeds require engineering consultation.
- Diversion Rollers: Use properly sized, smooth rollers with diameter minimum 15× cable diameter. Ensure bearings are well-maintained.
Reel and Drum Selection
- Core Diameter: Minimum 12× cable outer diameter for motorized reels
- Groove Design: Smooth, rounded grooves without sharp edges. Groove radius should accommodate cable diameter with minimal compression.
- First Layer Attachment: Securely clamp first layer to prevent slippage. Use proper cable glands rated for MV applications.
- Winding Tension: Maintain consistent moderate tension. Use level-winding systems for even distribution.
- Layer Separation: For multi-layer winding, consider layer separation to improve heat dissipation.
Electrical Termination Best Practices
- Cleanliness: Maintain absolute cleanliness during termination. Contamination can cause tracking and failure.
- Semiconductive Layer Removal: The outer semiconductive layer features “easy strip” design – remove cleanly per manufacturer instructions. Do not leave residual semiconductive material.
- Insulation Preparation: Cut EPR insulation cleanly with proper tools. Avoid nicks or stress concentrations.
- Stress Relief: Use properly sized stress cones or heat-shrink termination kits rated for the cable voltage.
- Shield Grounding: Properly ground the earth conductor at both ends. Ensure continuity.
- Termination Kits: Use only manufacturer-approved or equivalent MV cable termination kits appropriate for EPR insulation.
Environmental Considerations
- Temperature Monitoring: In flexing applications, limit ambient temperature to +60°C maximum. Install temperature monitoring if approaching limits.
- Moisture Protection: While moisture-resistant, ensure proper sealing at cable entries and terminations to prevent water ingress.
- Chemical Exposure: Although oil-resistant, avoid prolonged contact with aggressive solvents, acids, or alkalis not specified in technical documentation.
- UV Exposure: UV-resistant but periodic inspection recommended for continuously exposed outdoor installations.
- Salt Spray: In marine environments, increase inspection frequency and ensure terminations are properly sealed.
Maintenance Requirements
- Regular Inspection Schedule:
- Visual inspection: Every 1-3 months depending on duty cycle
- Detailed inspection: Every 6-12 months
- Electrical testing: Annually or per local regulations
- Visual Inspection Points:
- Outer sheath condition (cracks, cuts, abrasion)
- Cable deformation or unusual bending
- Proper winding on reel (no overlapping or crossing)
- Termination integrity and signs of tracking
- Support and guiding system condition
- Electrical Testing (De-energized):
- Insulation resistance testing at appropriate DC voltage (typically 2-5× rated voltage)
- Minimum acceptable: 1000 MΩ·km at 20°C (higher for MV cables)
- Conductor continuity testing
- Earth conductor continuity and resistance
- Mechanical Assessment:
- Reel bearing condition and smooth rotation
- Diversion roller condition and alignment
- Cable guide system proper operation
- Tensioning system calibration
- Documentation: Maintain detailed maintenance logs including inspection dates, test results, and any repairs or modifications.
7. Common Problems and Troubleshooting
Problem 1: Insulation Breakdown / Partial Discharge
Symptoms: Electrical faults, ground fault trips, audible crackling or buzzing, ozone smell, visible corona discharge.
Common Causes:
- Moisture ingress through damaged outer sheath or improper terminations
- Mechanical damage to insulation from excessive bending or crushing
- Contamination during termination (dirt, moisture, oils)
- Improper termination technique leaving voids or stress points
- Overheating degrading insulation properties
- Aging and thermal cycling in harsh environments
Solutions:
- Immediate de-energization and isolation of faulty section
- Perform insulation resistance and partial discharge testing to locate fault
- Replace damaged cable section – MV cable repairs are generally not recommended
- Inspect and re-terminate if fault is at termination point
- Improve environmental sealing and protection
- Implement preventive maintenance program with regular testing
Problem 2: Conductor Breakage / Open Circuit
Symptoms: Loss of power to equipment, phase imbalance, unusual operating behavior.
Common Causes:
- Bending radius below minimum specification (12× diameter)
- Excessive tensile loads beyond 20 N/mm² continuous capacity
- Fatigue from excessive duty cycle or improper reel operation
- Damage from sharp objects or improper handling during installation
- Corrosion at termination points (moisture ingress)
Solutions:
- Conduct continuity testing to identify broken phase(s)
- Verify and correct reel geometry and bending radii
- Reduce load or select cable with higher tensile capacity
- Replace damaged cable section
- Improve cable handling and installation procedures
- Assess duty cycle and consider cable with enhanced flexibility
Problem 3: Outer Sheath Damage / Abrasion
Symptoms: Visible wear, cracks, or cuts in black PCP outer sheath, potential exposure of red inner sheath.
Common Causes:
- Friction against sharp or abrasive surfaces
- Improper guide systems allowing cable to rub against structures
- Chemical attack from incompatible substances
- Excessive UV exposure in extreme conditions (rare due to UV resistance)
- Operation at temperatures exceeding +60°C in flexing applications
Solutions:
- Inspect exposed areas for damage to inner sheath and insulation
- If only outer sheath damaged and inner sheath intact, monitor closely
- If inner sheath compromised, plan for cable replacement
- Install proper cable guides and protection systems
- Identify and eliminate sources of abrasion or chemical exposure
- Improve maintenance procedures to catch damage early
Problem 4: Overheating
Symptoms: Hot cable surface, thermal shutdown, softened sheath, discoloration, insulation degradation.
Common Causes:
- Current load exceeding ampacity rating for actual conditions
- Poor heat dissipation from tight winding on reel (multiple layers)
- Ambient temperature approaching or exceeding +60°C in flexing applications
- Inadequate ventilation around reel
- Poor electrical connections at terminations causing resistive heating
- Unbalanced loading causing excess current in one phase
Solutions:
- Immediately reduce load or shut down system
- Measure actual current draw and compare to rated ampacity
- Recalculate ampacity based on actual ambient temperature and installation method
- Select larger conductor cross-section if load requirements unchanged
- Improve ventilation and heat dissipation
- Apply derating factors for multi-layer winding
- Inspect and remake all terminations using proper techniques and materials
- Use thermal imaging to identify hot spots
Problem 5: Cable Twisting / Loss of Torsional Rigidity
Symptoms: Visible spiral deformation, uneven winding, cable “birds nesting” on reel.
Common Causes:
- Improper initial installation with pre-existing twist
- Damage to or failure of anti-torsion textile braid
- Reel rotation direction mismatched to cable lay
- Free-hanging sections that can rotate under load
- Exceeding ±100°/m torsional stress specification
Solutions:
- Install cable without pre-twist; maintain natural lay during installation
- Verify correct reel rotation direction
- Install torque-limiting devices or swivels where appropriate
- Replace cable if anti-torsion braid is damaged (cannot be repaired)
- Assess duty cycle and consider cable with enhanced torsional capacity
Problem 6: Grounding System Failure
Symptoms: Ground fault detection system alarms, electrical noise, shock hazard, equipment malfunctions.
Common Causes:
- Damaged earth conductor from mechanical stress
- Poor termination of ground connections
- Corrosion at ground connection points
- Inadequate bonding between cable sections or equipment
Solutions:
- Immediately de-energize system – loss of ground is critical safety hazard
- Test earth conductor continuity and resistance
- Inspect and remake all ground connections
- Ensure proper bonding at all joints and terminations
- Replace cable if earth conductor is damaged within cable body
- Implement regular ground testing as part of maintenance program
9. Fiber Optic Integration (FO Variants)
Integrated Optical Fiber Communication
The R-(N)TSCGEWOEU FO variants include 12 optical fibers integrated into the cable structure, providing high-capacity data transmission alongside power distribution. This eliminates the need for separate communication cables and simplifies installation.
Fiber Optic Specifications
- Fiber Count: 12 optical fibers (standard configuration)
- Fiber Type: Typically single-mode or multimode (specify when ordering)
- Protection: Fibers are housed in protective tube within cable core
- Positioning: Located in cable interstices to minimize mechanical stress
- Applications: SCADA systems, video surveillance, remote monitoring, control signals, Ethernet communication
FO Variant Configuration Changes
In FO variants, the earth conductor arrangement is modified:
- Standard cables: Earth conductor divided into 3 parts in interstices
- FO cables: Earth conductor halved (2 parts) with optical fiber tube occupying remaining interstice
- This maintains electrical safety while accommodating fiber optics
Available FO Configurations (Examples)
| Voltage Rating | Cross-Section | Order Code Example | Outer Diameter |
|---|---|---|---|
| 3.6/6 kV | 3×50+2G25/2+12FO | 0684-4G50+12FO# | 43.8 – 46.8 mm |
| 6/10 kV | 3×95+2G50/2+12FO | 0685-4G95+12FO# | 54.0 – 58.0 mm |
| 8.7/15 kV | 3×120+2G70/2+12FO | 0686-4G120+12FO# | 62.9 – 66.9 mm |
| 12/20 kV | 3×150+2G70/2+12FO | 0687-4G150+12FO# | 69.6 – 73.6 mm |
FO Handling Precautions
- Never exceed minimum bending radius – fiber optics are more sensitive to bending than conductors
- Avoid excessive tensile stress which can damage optical fibers
- Use qualified fiber optic technicians for termination and splicing
- Protect fiber terminations from moisture and contamination
- Test optical performance after installation and periodically
- Clearly label and document fiber assignments
8. Cable Selection and Specification Guide
Voltage Rating Selection
| System Voltage | Recommended Cable Rating | Notes |
|---|---|---|
| 3.3 kV | 3.6/6 kV | Standard low MV systems |
| 6.0 kV, 6.6 kV | 6/10 kV | Common industrial distribution |
| 11 kV, 13.2 kV, 13.8 kV | 8.7/15 kV | Medium voltage distribution |
| 15 kV, 20 kV, 22 kV | 12/20 kV | Higher voltage applications |
Conductor Cross-Section Selection
Selection Criteria:
- Calculate Load Current: Sum all connected loads plus 20-30% safety margin
- Check Ampacity: Select cross-section with ampacity ≥ load current
- Apply Derating: Consider ambient temperature, winding layers, duty cycle
- Verify Voltage Drop: Ensure voltage drop at load is acceptable (typically < 3-5%)
- Check Tensile Load: Verify cable weight + dynamic loads don’t exceed rated tensile capacity
- Consider Short-Circuit Rating: Ensure cable can withstand fault currents
Application Decision Matrix
| Application Type | Recommended Configuration | Key Considerations |
|---|---|---|
| Small Container Cranes | 3.6/6 kV, 3×50-70 mm² | Low mounting height, moderate duty |
| Large Container Cranes | 6/10 kV, 3×95-150 mm² | High power demand, data integration |
| Mining Equipment | 6/10 or 8.7/15 kV, 3×70-120 mm² | Harsh environment, high reliability |
| Stackers & Reclaimers | 6/10 kV, 3×95-150 mm² | Long travel distances, medium speeds |
| Ship Unloaders | 6/10 or 8.7/15 kV, 3×120-150 mm² | Marine environment, high power |
When to Choose R-(N)TSCGEWOEU Over Alternatives
Choose R-(N)TSCGEWOEU Protolon when:
- Medium voltage power distribution (3.6 kV to 20 kV) required on mobile equipment
- Motorized cable reel application with low to medium duty cycle
- Space limitations require compact cable and reel dimensions
- Cost-effective solution needed without compromising reliability
- Integrated fiber optic communication is beneficial (FO variants)
- Operating temperatures in flexing applications stay below +60°C
- Travel speeds up to 80 m/min
- One diversion roller assembly maximum
- Oil resistance and environmental durability required
Consider alternatives when:
- Voltage requirements exceed 20 kV (request higher voltage grades)
- Extreme heavy-duty cycle applications (consider more robust designs)
- Travel speeds significantly exceed 80 m/min
- Multiple diversion points or complex routing required
- Operating temperatures exceed +60°C in flexing applications
- Static installation without flexing (use standard MV power cables)
- Budget allows for more advanced designs with enhanced features
Ordering Information
When ordering, please specify:
- Voltage rating (3.6/6, 6/10, 8.7/15, or 12/20 kV)
- Conductor cross-section (25, 35, 50, 70, 95, 120, or 150 mm²)
- With or without optical fibers (FO variants)
- If FO: fiber type (single-mode or multimode)
- Cable length required (minimum order 200 meters)
- Specific application details and operating conditions
- Any special requirements (sheath color, testing, certification)
Example order code: 0685-4G95+12FO#
- 0685 = 6/10 kV voltage rating
- 4G95 = 3 power conductors + ground, 95 mm² cross-section
- 12FO = 12 optical fibers included
Delivery times vary by configuration – contact sales for current lead times.
Technical Support and Engineering Services
Anhui Feichun Special Cable Co., Ltd. provides comprehensive engineering support for high voltage cable systems, including:
Pre-Sales Engineering:
- System voltage and current calculations
- Cable selection and sizing for specific applications
- Ampacity calculations for actual operating conditions
- Voltage drop analysis and power quality assessment
- Mechanical load analysis and tensile strength verification
- Reel and drum specification guidance
- Cost-benefit analysis and lifecycle cost modeling
Installation Support:
- Installation procedure documentation
- Termination and jointing technical guidance
- On-site commissioning support (available)
- Testing and inspection protocols
- Training for maintenance personnel
Custom Solutions:
- Modified conductor configurations and cross-sections
- Alternative voltage ratings (higher than 20 kV available)
- Custom fiber optic configurations (beyond 12 fibers)
- Special sheath compounds for extreme environments
- Hybrid cables with integrated control circuits
- Application-specific testing and type approval
- Third-party certification to customer specifications
Comparison: R-(N)TSCGEWOEU vs. Alternative MV Cable Types
| Feature | R-(N)TSCGEWOEU Protolon | Standard MV Trailing Cable | Heavy-Duty Reeling Cable |
|---|---|---|---|
| Voltage Range | 3.6/6 to 12/20 kV+ | 3.6/6 to 6/10 kV | 6/10 to 18/30 kV |
| Insulation Type | EPR (triple extruded) | EPR or XLPE | EPR with enhanced protection |
| Flexibility | FS (Super-flexible) | Class 5 | Class 5 or FS |
| Torsional Protection | Vulcanized textile braid | Limited or none | Enhanced braid systems |
| Max Travel Speed | 80 m/min | 40-60 m/min | 120+ m/min |
| Duty Cycle | Low to medium | Light | Heavy continuous |
| Fiber Optic Option | Yes (12 FO standard) | Typically no | Yes (custom) |
| Temperature Range (Flexing) | -25°C to +60°C | -25°C to +50°C | -40°C to +80°C |
| Cost | Moderate | Lower | Higher |
| Ideal Application | Container cranes, medium-duty mobile equipment | Light mobile equipment | High-performance cranes, extreme duty |
Quality Assurance and Testing
Factory Testing and Quality Control
Every cable undergoes rigorous testing before shipment:
- Conductor Resistance: DC resistance per DIN VDE 0295
- Insulation Resistance: High-voltage megger testing
- High Voltage Test: AC voltage test per DIN VDE 0250-813
- Partial Discharge Test: For critical applications
- Dimensional Verification: Diameter, concentricity, insulation thickness
- Flexibility Test: Bending test to verify mechanical properties
- Visual Inspection: Surface quality, markings, color coding
- Optical Fiber Testing: For FO variants – insertion loss, return loss, continuity
Type Testing and Certification
Type test reports available demonstrating compliance with:
- DIN VDE 0250-813 comprehensive type testing
- IEC 60332-1 flame retardancy testing
- Mechanical flexing cycle testing (millions of cycles)
- Environmental aging tests (temperature cycling, UV exposure, chemical resistance)
- Tensile strength and torsional rigidity verification
- Short-circuit withstand capability
Environmental Sustainability
Feichun’s commitment to environmental responsibility:
- CFC-Free Manufacturing: No chlorofluorocarbons used in production processes
- Recyclable Materials: Copper conductors and polymer sheaths can be recycled at end of life
- Long Service Life: Durable construction reduces replacement frequency and waste
- Energy Efficiency: Low electrical resistance minimizes transmission losses
- Halogen-Free Options: Available for applications requiring low smoke and toxic gas emission
- RoHS Compliance: Available on request for European markets
- REACH Compliance: Materials conform to EU chemical regulations
Frequently Asked Questions (FAQ)
Q1: Can this cable be used for festoon systems?
A: While primarily designed for motorized reels, the cable can be used in festoon systems with proper support trolleys and adequate spacing. Consult engineering for specific festoon applications.
Q2: What is the difference between the voltage ratings?
A: Higher voltage ratings have thicker EPR insulation layers. The 3.6/6 kV cable has approximately 2.5mm insulation, while 12/20 kV has approximately 5.5mm, resulting in larger overall diameter and weight.
Q3: Can I use a 6/10 kV cable on a 3.3 kV system?
A: Yes, using a higher voltage-rated cable is acceptable and provides additional safety margin. However, the cable will be larger and heavier than necessary.
Q4: How do I determine if my application is “low to medium duty cycle”?
A: Low duty: < 15% operating time, < 20 starts per hour. Medium duty: 15-40% operating time, 20-60 starts per hour. Contact engineering if your duty cycle exceeds these parameters.
Q5: What is the expected service life?
A: With proper installation and maintenance, expect 10-15 years in medium-duty applications. Service life depends heavily on duty cycle, environmental conditions, and maintenance quality.
Q6: Can the cable be repaired if damaged?
A: Minor outer sheath damage can sometimes be repaired with vulcanizing tape or heat-shrink. Damage to insulation or conductors requires replacement. MV cable splicing requires specialized kits and qualified technicians.
Q7: Do I need special tools for termination?
A: Yes, MV cable termination requires cable stripping tools, stress cone kits, crimping tools for lugs, and testing equipment. Only qualified MV electricians should perform terminations.
Q8: What maintenance is required for the fiber optic version?
A: Same mechanical/electrical maintenance as standard version, plus periodic optical power testing and connector cleaning. Fiber terminations should be protected from moisture and contamination.
Conclusion
The R-(N)TSCGEWOEU Protolon (M)-R / W-9 high voltage reeling cable represents a sophisticated engineering solution for medium voltage power distribution in demanding mobile industrial applications. Its innovative sandwich-construction with vulcanized anti-torsion braid, triple-extruded EPR insulation system, and super-flexible FS conductors provide exceptional reliability and longevity in container crane, mining, and heavy equipment applications.
Available in four voltage ratings from 3.6/6 kV to 12/20 kV (with higher voltages on request), conductor cross-sections from 25 mm² to 150 mm², and optional integrated 12-fiber optic communication, the cable offers tremendous application versatility. The ability to combine power and data transmission in a single cable simplifies installation and reduces system complexity.
While designed for low to medium duty cycle applications with moderate travel speeds (up to 80 m/min), the cable provides an optimal balance between performance, reliability, and cost-effectiveness for motorized reel systems. The EPR insulation’s “easy strip” semiconductive layer significantly simplifies field termination compared to alternative designs.
Key selection criteria: If your application involves medium voltage mobile equipment on cable reels, operating temperatures below 60°C in flexing service, travel speeds up to 80 m/min, and you require integrated data transmission with reliable mechanical performance at a competitive price point, the R-(N)TSCGEWOEU Protolon cable is an excellent choice.
For applications exceeding these parameters – such as very high duty cycles, speeds above 80 m/min, extreme temperatures, or multiple diversion points – consult Feichun’s engineering team for alternative cable recommendations or custom solutions tailored to your specific requirements.
