AS/NZS 2802 Type 440F and 450F Fibre-Optic Reeling Cable
Medium- and high-voltage electro-optic reeling and trailing cable engineered to AS/NZS 2802 for open-cut electric rope shovels, walking draglines, bucket-wheel excavators, stacker-reclaimers and port ship loaders from 3.3/3.3 kV to 33/33 kV. Combines three composite-screened R-EP-90 EPR power cores, Split-earth or pilot interstices and a crush-resistant 6 to 24 fibre optical sub-unit inside a reinforced double HD-85-PCP sheath. MOQ 50 m; lead time 7 to 45 working days.
High-capacity open-cut draglines, electric rope shovels, rail-mounted stacker-reclaimers and automated ship loaders increasingly combine medium-voltage power reeling with high-speed optical fibre telemetry inside a single dynamic cable. AS/NZS 2802 Type 440F and Type 450F electro-optic reeling cables integrate three composite-screened R-EP-90 EPR power cores, interstitial pilot or earth elements and a dedicated impact-resistant optical fibre assembly in one torsion-stabilized round construction.
The engineering distinction between Type 440F and Type 450F follows the AS/NZS 2802 insulation wall classification. Type 440F utilizes Class 2 thicker radial R-EP-90 EPR insulation walls (for example 7.6 mm at 11/11 kV) engineered for rugged surface mine trailing and slow-to-medium speed drum reeling where mechanical dielectric margin is prioritized. Type 450F utilizes Class 1 reduced-wall R-EP-90 EPR insulation (for example 5.5 mm at 11/11 kV), reducing overall cable diameter and drum weight on long-travel monospiral or cylindrical reeling drums up to 33/33 kV.
In both families, the optical fibre sub-unit houses 6, 12 or 24 single-mode OS2 (ITU-T G.652.D) or multimode OM3/OM4 fibres cushioned by aramid reinforcement yarns and an elastomeric jacket. An open-weave synthetic anti-torsion braid vulcanized between the inner and outer extra-heavy-duty HD-85-PCP polychloroprene sheaths prevents core birdcaging and optical attenuation under cyclic reeling tension. TEBAOFLEX supplies custom reeling lengths from a 50 m MOQ with a 7 to 45 working day lead time.
Explore the mining and tunneling cable range for related configurations.
Construction
The representative horizontal sample illustrates the AS/NZS 2802 Type 450.11F 11/11 kV electro-optic reeling construction, showing three flexible tinned copper power cores with triple-extruded semi-conducting screens and Class 1 R-EP-90 EPR insulation, composite tinned-copper and polyester earth screens over each phase, two interstitial pilot cores, one reinforced optical fibre sub-unit in the third interstice, inner PCP bedding, anti-torsion braid and heavy-duty HD-85-PCP outer sheath.
| Component | Material and construction |
|---|---|
| Power Conductors (3 x Class 5 Tinned Copper) | Flexible stranded annealed tinned copper conductors (25 mm2 to 185 mm2) complying with AS/NZS 1125 Class 5 for dynamic reeling and trailing duty. |
| Triple-Extruded Dielectric System | Extruded semi-conducting conductor screen, thermoset R-EP-90 EPR insulation (Class 2 wall for Type 440F; Class 1 reduced wall for Type 450F) per AS/NZS 3808, and extruded semi-conducting core screen. |
| Composite Phase Earth Screens | Helically applied tinned copper wire and polyester yarn composite braid over each of the three power cores providing fault-current return and radial field containment. |
| Interstitial Pilot Conductors | Two EPR-insulated flexible tinned copper pilot cores laid in two outer interstices for earth-continuity and reeling limit-switch interlocking. |
| Optical Fibre Sub-Unit (F Suffix) | Aramid-reinforced, elastomeric-jacketed optical unit occupying the third outer interstice and containing 6, 12 or 24 OS2 single-mode or OM3/OM4 multimode optical fibres. |
| Semi-Conductive Cradle & Inner Sheath | Central semi-conductive elastomeric cradle profile and extruded HD-85-PCP inner bedding locking the core lay against torsional displacement. |
| Anti-Torsion Braid & HD-85-PCP Outer Sheath | High-tenacity polyamide anti-torsion braid bonded between the inner bedding and the extra-heavy-duty oil-, UV- and abrasion-resistant HD-85-PCP outer sheath. |
Applications
Specify AS/NZS 2802 Type 440F and Type 450F electro-optic cables where medium- and high-voltage surface mining or bulk terminal machinery requires simultaneous reeling power and EMI-immune fiber optic data links.
- Open-cut walking draglines, electric rope shovels and hydraulic face shovels operating at 6.6/6.6 kV, 11/11 kV or 22/22 kV with real-time fleet telemetry and high-definition optical video.
- Rail-mounted iron-ore and coal stacker-reclaimers, bucket-wheel excavators and port ship loaders requiring long-travel monospiral or level-wind reeling up to 33/33 kV.
- Mobile in-pit crushing and conveying (IPCC) stations and overland hopper cars integrating medium-voltage transformer feeders with redundant PLC fiber rings.
- Direct fiber-optic upgrades from copper-only Type 440 or Type 450 reeling cables when retrofitting legacy open-cut and port bulk-handling machines for autonomous operation.
Related selection resources
- Mining and tunneling cable engineering solutions
- Mining reeling cable anti-torsion braid and replacement sizing guide
- AS/NZS 2802 Type 440 composite screened mining cable (1.1 to 22 kV)
- AS/NZS 2802 Type 450 Class 1 composite screened mining cable (3.3 to 33 kV)
- AS/NZS 1802 Type 230 and Type 235 Shuttle Car Reeling Cable
Specifications
| Parameter | Value |
|---|---|
| Design standard reference | Engineered to AS/NZS 2802, AS/NZS 1125 and AS/NZS 3808 with ITU-T G.652.D or ISO/IEC 11801 optical fibres |
| Rated voltage classes | 3.3/3.3 kV, 6.6/6.6 kV, 11/11 kV and 22/22 kV for Type 440F and Type 450F; 33/33 kV specific to Class 1 Type 450.33F |
| Type 440F vs Type 450F insulation wall | Type 440F uses Class 2 standard EPR wall thickness; Type 450F uses Class 1 reduced EPR wall thickness for compact reeling |
| Operating and short-circuit temperature | 90 C continuous conductor temperature and 250 C short-circuit conductor temperature (5 s max duration) |
| Minimum dynamic reeling bend radius | 10 x overall cable diameter during dynamic drum reeling and deflection sheave guidance |
| Commercial supply terms | Minimum order quantity 50 m; manufacturing lead time 7 to 45 working days with routine HV partial-discharge and OTDR test reports |
| Selection boundary vs Type 245F & Type 440/450 | Select Type 440F/450F for 3.3 kV to 33 kV surface reeling with optical fibres; select Type 245F for 1.1 to 3.3 kV underground coal longwall duty. |
| Cable Designation & Configuration | Voltage Rating | Power Core Area (mm²) | Conductor Stranding (No./mm) | Class 2 EPR Wall (mm) | Nominal Overall O.D. (mm) | Approx. Net Mass (kg/km) | Ampacity at 30 °C Ambient (A) | Min. Reeling Bend Radius (mm) |
|---|---|---|---|---|---|---|---|---|
| Type 440.3F 3x25 + 6/12F | 3.3/3.3 kV | 25 | 196/0.40 | 3.0 | 49.5 | 3580 | 145 | 500 |
| Type 440.3F 3x35 + 6/12F | 3.3/3.3 kV | 35 | 276/0.40 | 3.0 | 52.8 | 4260 | 175 | 530 |
| Type 440.6F 3x35 + 6/12F | 6.6/6.6 kV | 35 | 276/0.40 | 5.0 | 61.4 | 5480 | 175 | 615 |
| Type 440.6F 3x50 + 6/12F | 6.6/6.6 kV | 50 | 396/0.40 | 5.0 | 65.8 | 6520 | 210 | 660 |
| Type 440.11F 3x35 + 6/12F | 11/11 kV | 35 | 276/0.40 | 7.6 | 73.2 | 7450 | 180 | 735 |
| Type 440.11F 3x50 + 6/12F | 11/11 kV | 50 | 396/0.40 | 7.6 | 77.6 | 8590 | 215 | 780 |
| Type 440.11F 3x70 + 6/12F | 11/11 kV | 70 | 360/0.50 | 7.6 | 82.4 | 9980 | 265 | 825 |
| Type 440.22F 3x50 + 6/12F | 22/22 kV | 50 | 396/0.40 | 13.0 | 101.5 | 13850 | 220 | 1015 |
| Cable Designation & Configuration | Voltage Rating | Power Core Area (mm²) | Conductor Stranding (No./mm) | Class 1 EPR Wall (mm) | Nominal Overall O.D. (mm) | Approx. Net Mass (kg/km) | Ampacity at 30 °C Ambient (A) | Min. Reeling Bend Radius (mm) |
|---|---|---|---|---|---|---|---|---|
| Type 450.6F 3x35 + 12/24F | 6.6/6.6 kV | 35 | 276/0.40 | 3.4 | 55.2 | 4620 | 175 | 555 |
| Type 450.6F 3x50 + 12/24F | 6.6/6.6 kV | 50 | 396/0.40 | 3.4 | 59.6 | 5640 | 210 | 600 |
| Type 450.11F 3x35 + 12/24F | 11/11 kV | 35 | 276/0.40 | 5.5 | 64.0 | 6120 | 180 | 640 |
| Type 450.11F 3x50 + 12/24F | 11/11 kV | 50 | 396/0.40 | 5.5 | 68.4 | 7180 | 215 | 685 |
| Type 450.11F 3x70 + 12/24F | 11/11 kV | 70 | 360/0.50 | 5.5 | 73.2 | 8540 | 265 | 735 |
| Type 450.11F 3x95 + 12/24F | 11/11 kV | 95 | 475/0.50 | 5.5 | 78.5 | 10220 | 315 | 785 |
| Type 450.22F 3x50 + 12/24F | 22/22 kV | 50 | 396/0.40 | 9.0 | 84.6 | 10480 | 220 | 850 |
| Type 450.22F 3x70 + 12/24F | 22/22 kV | 70 | 360/0.50 | 9.0 | 89.4 | 11960 | 270 | 895 |
| Type 450.33F 3x50 + 12/24F | 33/33 kV | 50 | 396/0.40 | 13.0 | 102.0 | 14120 | 225 | 1020 |
| Type 450.33F 3x70 + 12/24F | 33/33 kV | 70 | 360/0.50 | 13.0 | 106.8 | 15780 | 275 | 1070 |
Current ratings are based on 30 C ambient air in free-air trailing configuration; apply AS/NZS 2802 drum-layer derating factors (typically 0.85 for 1 layer, 0.65 for 2 layers, 0.45 for 3 layers) when energized on cylindrical reels.
Specify the exact voltage code (.3F, .6F, .11F, .22F or .33F), optical fibre mode (OS2, OM3 or OM4) and fibre count (6F, 12F or 24F) when requesting factory drawings.
Standards
| Standard or specification | Application |
|---|---|
| AS/NZS 2802 | Electric cables — Reeling and trailing — For mining and general use (other than underground coal mining) from 1.1/1.1 kV to 33/33 kV. |
| AS/NZS 1125 | Conductors in insulated electric cables and flexible cords (Class 5 flexible tinned annealed copper). |
| AS/NZS 3808 | Insulating and sheathing materials for electric cables (R-EP-90 thermoset EPR insulation and HD-85-PCP heavy-duty sheath). |
| ITU-T G.652.D & ISO/IEC 11801 | Optical transmission and attenuation performance for integrated OS2 single-mode and OM3/OM4 multimode optical fibres. |
| AS/NZS 1660.5.6 | Single-cable vertical flame propagation test for elastomeric-sheathed reeling and trailing cables. |
Certifications and document support
TEBAOFLEX company certificates and quality system documentation
Standards New Zealand — AS/NZS 2802 Reeling and Trailing Mining Cable Standard
Related cable options
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Type 440 Composite Screened Mining Cable 1.1–22 kV
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Type 450 Class 1 Composite Screened Mining Cable 3.3/3.3–33/33 kV
A related cable option for a different application or duty profile.
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AS/NZS 1802 Type 245F and 241F Electro-Optic Mining Cable
A related cable option for a different application or duty profile.
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