Flat Type W 2-Conductor 2000V Mining Cable
Heavy-duty 2000 V two-conductor Flat Type W portable mining trailing cable without grounding conductor, designed and manufactured to ICEA S-75-381 / NEMA WC 58 across 4 AWG through 4/0 AWG. Engineered with two D-shaped 90 °C EPR-insulated rope-lay tinned-copper conductors (black and white) inside an extra-heavy-duty lead-cured CPE jacket for diode-grounded DC mining equipment, battery chargers and drilling rigs.
In North American underground coal and hard-rock mining, DC shuttle cars, roof bolters, haulage locomotives and scooptrams frequently operate on diode-grounded DC power systems where frame grounding is achieved through a polarized silicon grounding diode connected to the grounded negative conductor rather than a separate grounding wire. Flat Type W 2-Conductor 2000 V mining cable without ground is purpose-built for these two-wire DC trailing circuits, as well as heavy industrial battery chargers and oil drilling rig DC feeds.
Compared with 2-conductor Flat Type G cable (which adds a central shaped green ground core), 2-conductor Flat Type W without ground eliminates the third interstitial wire—reducing overall cable width by 18% to 22% (for example, 0.99 × 1.63 in vs 0.98 × 2.05 in at 2/0 AWG) so significantly longer cable lengths can be wound onto compact machine reels.
Each conductor from 4 AWG through 4/0 AWG is constructed from rope-lay-stranded annealed tinned copper per ASTM B172 (259 to 532 strands) and insulated with 90 °C Ethylene Propylene Rubber (EPR) in black and white. The two cores are extruded with mating D-shaped profiles that lock flat against each other inside the outer jacket, preventing core rotation, corkscrewing or shifting under heavy wheel runovers and tight sheave guidance.
An extra-heavy-duty lead-cured Chlorinated Polyethylene (CPE) outer jacket provides high compression-cut, impact, abrasion, oil, chemical, steam and sunlight resistance across a wide operating temperature range, with optional colored jackets, neoprene compounds or reflective stripes available.
Explore the mining and tunneling cable range for related configurations.
Construction
The representative cutaway illustrates a 2000 V 2-conductor Flat Type W portable mining cable without ground built to ICEA S-75-381, showing the two rope-lay-stranded tinned-copper conductors, mating D-shaped black and white EPR insulation and extra-heavy-duty lead-cured black CPE outer jacket.
| Component | Material and construction |
|---|---|
| Power Conductors (2 × DC / Single-Phase) | 4 AWG through 4/0 AWG annealed tinned copper, bunched wires, rope-lay-stranded per ASTM B172 (259 strands on 4 AWG–1/0 AWG; 329 on 2/0 AWG; 413 on 3/0 AWG; 532 on 4/0 AWG). |
| D-Shaped Core Insulation | 90 °C Ethylene Propylene Rubber (EPR) extruded in a flat-sided D-profile to prevent conductors from shifting or twisting under the jacket; color-coded black and white (0.060 in / 1.5 mm wall on 4–2 AWG; 0.080 in / 2.0 mm wall on 1–4/0 AWG). |
| Grounding / Pilot Core | None (2-conductor ungrounded construction specifically designed for diode-grounded DC mining trailing equipment; select Flat Type G 2C if a dedicated green grounding core is required). |
| Outer Jacket | Extra-heavy-duty lead-cured Chlorinated Polyethylene (CPE) compound bonded over the parallel D-cores for crush, runover, cut, oil and flame resistance (optional colored jacket, neoprene or reflective stripe). |
Applications
Specify 2-conductor Flat Type W 2000 V cable without ground for diode-grounded DC mining machinery, battery charging stations and compact flat-spooling trailing reels.
- Diode-grounded DC underground mining shuttle cars, roof bolters, cutting machines and utility vehicles.
- Mine battery charging stations, underground locomotive battery tenders and DC rectifier output leads.
- Onshore oil and gas drilling rig DC traction, draw-works and mud-pump auxiliary power drops.
- Heavy industrial DC magnet cranes, transfer cars and mobile reels where a narrow twin-core flat profile maximizes drum capacity.
Specifications
| Parameter | Value |
|---|---|
| Rated voltage and temperature | 2000 V; 90 °C maximum continuous conductor temperature (−40 °C cold bend). |
| Construction standard | Designed and manufactured in accordance with ICEA S-75-381 / NEMA WC 58 for portable mining cables; flame-retardant CPE jacket engineered to MSHA 30 CFR Part 18 flame test requirements. |
| Conductor range and stranding | 2 conductors from 4 AWG (259 strands) through 4/0 AWG (532 strands) rope-lay annealed tinned copper per ASTM B172. |
| Anti-shift core geometry | Mating D-shaped EPR insulation profiles lock the black and white conductors parallel inside the lead-cured CPE jacket without internal fillers. |
| Single-cable ampacity (90 °C / 40 °C) | 127 A (4 AWG) to 328 A (4/0 AWG) in free air per ICEA S-75-381 / NEMA WC 58 Table for two-conductor round and flat cables. |
| Minimum bending radius | 6 × cable minor dimension (height) per ICEA S-75-381 (3.7 in / 93 mm on 4 AWG up to 6.6 in / 167 mm on 4/0 AWG). |
| Selection boundary vs Flat Type G & 4/C Type W | Use 2/C Flat Type W for diode-grounded 2-wire DC trailing circuits; use 2/C Flat Type G when a separate 3rd grounding wire is required on DC machines; use 4/C Flat Type W for three-phase AC circuits with an insulated ground. |
| Designation | Conductor Size | Conductor Strand | Nom. Insulation Wall (in / mm) | Nom. Cable Dimensions H × W | Copper Weight (lbs/kft / kg/km) | Net Weight (lbs/kft / kg/km) | Ampacity 90 °C / 40 °C (A) |
|---|---|---|---|---|---|---|---|
| 2/C 4 AWG Flat Type W | 4 AWG | 259 | 0.060 / 1.5 | 0.61 × 1.05 in (15.5 × 26.7 mm) | 271 / 403 | 550 / 818 | 127 |
| 2/C 3 AWG Flat Type W | 3 AWG | 259 | 0.060 / 1.5 | 0.68 × 1.14 in (17.3 × 29.0 mm) | 329 / 489 | 675 / 1005 | 145 |
| 2/C 2 AWG Flat Type W | 2 AWG | 259 | 0.060 / 1.5 | 0.73 × 1.24 in (18.5 × 31.5 mm) | 412 / 613 | 850 / 1265 | 167 |
| 2/C 1 AWG Flat Type W | 1 AWG | 259 | 0.080 / 2.0 | 0.81 × 1.40 in (20.6 × 35.6 mm) | 523 / 778 | 1040 / 1550 | 191 |
| 2/C 1/0 AWG Flat Type W | 1/0 AWG | 259 | 0.080 / 2.0 | 0.93 × 1.51 in (23.6 × 38.2 mm) | 657 / 978 | 1285 / 1915 | 217 |
| 2/C 2/0 AWG Flat Type W | 2/0 AWG | 329 | 0.080 / 2.0 | 0.99 × 1.63 in (25.1 × 41.4 mm) | 835 / 1242 | 1530 / 2280 | 250 |
| 2/C 3/0 AWG Flat Type W | 3/0 AWG | 413 | 0.080 / 2.0 | 1.03 × 1.77 in (26.2 × 45.0 mm) | 1048 / 1560 | 1810 / 2694 | 286 |
| 2/C 4/0 AWG Flat Type W | 4/0 AWG | 532 | 0.080 / 2.0 | 1.10 × 1.89 in (27.9 × 48.0 mm) | 1363 / 2028 | 2175 / 3237 | 328 |
| Conductor Size | Free-Air Ampacity (A) | 1-Layer Reel (× 0.85) | 2-Layer Reel (× 0.65) | 3-Layer Reel (× 0.45) | 4-Layer Reel (× 0.35) | Min. Bend Radius (6 × H) | Width Savings vs 2/C Flat Type G (With Ground) |
|---|---|---|---|---|---|---|---|
| 4 AWG | 127 A | 108.0 A | 82.6 A | 57.2 A | 44.5 A | 3.7 in (93 mm) | 0.61 × 1.05 in (vs 0.61 × 1.32 in on 2/C Flat Type G) |
| 3 AWG | 145 A | 123.3 A | 94.3 A | 65.3 A | 50.8 A | 4.1 in (104 mm) | 0.68 × 1.14 in (vs 0.65 × 1.44 in on 2/C Flat Type G) |
| 2 AWG | 167 A | 142.0 A | 108.6 A | 75.2 A | 58.5 A | 4.4 in (111 mm) | 0.73 × 1.24 in (vs 0.72 × 1.55 in on 2/C Flat Type G) |
| 1 AWG | 191 A | 162.4 A | 124.2 A | 86.0 A | 66.9 A | 4.9 in (124 mm) | 0.81 × 1.40 in (vs 0.81 × 1.73 in on 2/C Flat Type G) |
| 1/0 AWG | 217 A | 184.5 A | 141.1 A | 97.7 A | 76.0 A | 5.6 in (142 mm) | 0.93 × 1.51 in (vs 0.90 × 1.89 in on 2/C Flat Type G) |
| 2/0 AWG | 250 A | 212.5 A | 162.5 A | 112.5 A | 87.5 A | 5.9 in (151 mm) | 0.99 × 1.63 in (vs 0.98 × 2.05 in on 2/C Flat Type G) |
| 3/0 AWG | 286 A | 243.1 A | 185.9 A | 128.7 A | 100.1 A | 6.2 in (157 mm) | 1.03 × 1.77 in (vs 1.03 × 2.21 in on 2/C Flat Type G) |
| 4/0 AWG | 328 A | 278.8 A | 213.2 A | 147.6 A | 114.8 A | 6.6 in (167 mm) | 1.10 × 1.89 in (vs 1.10 × 2.40 in on 2/C Flat Type G) |
Ampacities are based on a conductor temperature of 90 °C and an ambient air temperature of 40 °C per ICEA S-75-381 / NEMA WC 58; for ambient temperatures other than 40 °C, multiply by 1.26 (10 °C), 1.18 (20 °C), 1.10 (30 °C) or 0.90 (50 °C).
All dimensions and weights are nominal and subject to standard industry tolerances; cut lengths are supplied on non-returnable reels with a ±5% length tolerance.
Where underground mine regulations require a separate metallic equipment grounding conductor in addition to the two DC power conductors, specify Flat Type G 2C with Ground.
Standards
| Standard or specification | Application |
|---|---|
| ICEA S-75-381 / NEMA WC 58 | Portable and power feeder cables for use in mines and similar applications (2000 V Type W flat construction, dimensions and ampacity). |
| ASTM B172 & ASTM B33 | Rope-lay-stranded bunched annealed tinned copper conductors for heavy-duty flexing service. |
| MSHA 30 CFR Part 18 | Flame test profile for underground mining trailing cables (confirm MSHA acceptance marking requirements during RFQ). |
NEMA / ICEA S-75-381 (NEMA WC 58) portable mining cable standard
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