(N)TSCGEWOEU LWL WR — TEBAOFLEX MV Reeling Cable with Integrated Fibre Optics
Why Combine Power and Fibre Optics in One Cable
Large mobile machines such as stackers, reclaimers, ship loaders, and draglines require both medium voltage power and high-bandwidth data communication for drive control, condition monitoring, CCTV, and remote operation. Running separate power and fibre optic cables in a single reeling system creates entanglement issues, increases drum size, and doubles installation time. The (N)TSCGEWOEU LWL WR solves this by embedding optical fibres directly into the MV power cable construction, delivering both functions through one cable on one drum.
What LWL WR Means
LWL is the German abbreviation for Lichtwellenleiter (fibre optic waveguide). WR designates the reinforced reeling variant. The optical fibres are integrated into the cable’s central or interstitial zone, protected by a rubber compound buffer and the same anti-torsion and outer sheath system as the standard (N)TSCGEWOEU.
Fibre Optic Specifications
| Parameter | Available Options |
|---|---|
| Fibre Type | 50/125 µm multimode, 62.5/125 µm multimode, 9/125 µm singlemode |
| Fibre Count | 2, 4, 6, 8, or 12 fibres per cable (custom counts available) |
| Attenuation | ≤ 3.0 dB/km (multimode 850nm), ≤ 1.0 dB/km (singlemode 1310nm) |
| Buffer | Tight buffer with rubber compound over-buffer |
| Position | Central or interstitial lay-up within power core assembly |
Construction
| Layer | Material |
|---|---|
| Phase Conductor | Extra-fine stranded tinned copper, Class 5 (VDE 0295 / IEC 60228) |
| Insulation | High-grade EPR/HEPR compound (at least 3GI3 per VDE 0207-21) |
| Semi-Conductive Layers | Extruded inner and outer semi-conductive rubber, cold strippable |
| Earth Conductors | 3 x tinned copper Class 5, split in core interstices |
| Central Area | Rubber compound buffer surrounding fibre optic element(s) |
| Fibre Optic Elements | Tight buffered fibres in rubber over-buffer, central or interstice position |
| Inner Sheath | EPR based 5GM3 double layer, also serving as water barrier |
| Anti-Torsion Braid | Reinforced polyester thread braid, vulcanized bonded between sheaths |
| Outer Sheath | 5GM5 heavy-duty PCP based rubber compound, bright red |
Core Configuration: 3 Power + 3 Earth + Fibre Optics
Technical Specifications
| Parameter | Value |
|---|---|
| Rated Voltage (Uo/U) | 3.6/6kV — 6/10kV — 8.7/15kV — 12/20kV |
| Design Standard | DIN VDE 0250-813 |
| Conductor Standard | VDE 0295 / IEC 60228 Class 5 |
| Max Conductor Temperature | +90°C |
| Max Short Circuit Temperature | +250°C |
| Ambient Temperature (Fixed) | -40°C to +80°C |
| Ambient Temperature (Mobile) | -25°C to +80°C |
| Min Bending Radius (Fixed) | 6 x OD |
| Min Bending Radius (Flexing) | 10 x OD |
| Max Working Speed | 120 m/min |
| Max Torsional Stress | ±25°/m |
| Max Tensile Load | 20 N/mm² |
| Flame Retardant | IEC 60332-1-2 / EN 60332-1-2 |
| Oil Resistance | DIN EN 60811-404 |
| Weather Resistance | Unrestricted outdoor/indoor, UV, ozone, moisture resistant |
| Outer Sheath Colour | Bright red (RAL 3000) |
| Outer Sheath Compound | 5GM5 per DIN VDE 0207-21 |
Dimensional Data — Example 3.6/6 kV with 4 FO
| Cross Section (mm²) | Fibre Count | Outer Diameter (mm) | Weight (kg/km) |
|---|---|---|---|
| 3×25 + 3×16/3E + 4 FO | 50/125 | 44 | 3,500 |
| 3×35 + 3×16/3E + 4 FO | 50/125 | 47 | 4,100 |
| 3×50 + 3×25/3E + 4 FO | 50/125 | 51 | 4,900 |
| 3×70 + 3×35/3E + 4 FO | 50/125 | 55 | 5,900 |
| 3×95 + 3×50/3E + 4 FO | 62.5/125 | 60 | 7,200 |
| 3×120 + 3×70/3E + 4 FO | 62.5/125 | 65 | 8,600 |
| 3×150 + 3×70/3E + 6 FO | 9/125 SM | 70 | 10,200 |
Dimensional data for 6/10kV, 8.7/15kV, and 12/20kV grades and alternate fibre configurations available on request.
Key Advantages of the Integrated Design
Single Cable, Single Drum — Eliminates the need for a separate fibre optic cable and second reel, reducing drum size and simplifying cable management on mobile machines.
Shared Mechanical Protection — The optical fibres benefit from the same anti-torsion braid, double-layer sheath system, and 5GM5 outer sheath that protect the power cores, enabling fibre optic communication in environments where standalone fibre cables would fail.
Field-Terminable Fibres — The tight-buffered fibre design allows on-site termination using standard connectors, avoiding the need for splice closures or specialised fusion splicing equipment on the machine.
VDE Certified Power Section — The power transmission core is fully VDE 0250-813 certified, identical to the standard (N)TSCGEWOEU, ensuring no compromise on electrical safety or mechanical ratings.
Why Choose TEBAOFLEX (N)TSCGEWOEU LWL WR
TEBAOFLEX manufactures this integrated power-fibre cable in our ISO 9001 certified facility. Each cable is tested for conductor resistance, high voltage withstand, and optical continuity before dispatch. The fibre optic elements are factory-tested for attenuation and end-to-end continuity. For new machine builds or retrofit projects where adding a separate data cable reel is not feasible, the LWL WR variant provides a single-drum solution for both power and data.
Standards and Certifications
| Standard | Scope |
|---|---|
| DIN VDE 0250-813 | Cable design and testing |
| IEC 60228 / VDE 0295 Class 5 | Flexible conductor |
| IEC 60332-1-2 | Flame retardant |
| DIN EN 60811-404 | Oil resistance |
| IEC 60793 | Optical fibre performance |
| RoHS | Compliance |
| ISO 9001:2015 | TEBAOFLEX quality management |
Application Environments
| Application | Benefit of Integrated FO |
|---|---|
| Stacker and reclaimer systems | Real-time position feedback and drive control over single cable |
| Ship loaders and unloaders | CCTV video + MV power in one drum for boom tip cameras |
| Draglines and rope shovels | Condition monitoring data from onboard sensors |
| Mobile crushers and conveyors | Remote SCADA communication without separate data cable |
| Port cranes and gantry cranes | Control signal transmission alongside MV drive power |
| Automated mining equipment | High-bandwidth data for autonomous operation systems |
