AS/NZS 2802 Type 409.1 and Type 410 Surface Mining Cable

Open-cut metalliferous mines, quarries, port bulk-handling yards and surface dewatering pump stations operating at 1.1/1.1 kV require heavier Class 2 radial insulation walls and thicker outer sheaths than underground coal face cables to withstand surface rock crushing, UV solar radiation and crawler run-over. AS/NZS 2802 defines Type 409.1 and Type 410.1 specifically for 1.1/1.1 kV surface mining, general industrial and non-coal underground metalliferous trailing and reeling service.

Type 409.1 is the 1.1/1.1 kV member of the AS/NZS 2802 Type 409 screened family, featuring three flexible Class 5 tinned copper power cores insulated with Class 2 thick-wall R-EP-90 EPR (2.2 mm to 2.8 mm radial wall vs 1.6 mm on AS/NZS 1802 Type 209), individual semi-conducting and tinned-copper/polyester composite phase screens, two interstitial earth cores and one pilot conductor. Type 410.1 provides an unscreened 1.1/1.1 kV Class 2 thick-wall R-EP-90 EPR construction with three power cores, one full-sized earth core and one pilot core (or four power/earth cores plus central pilot) where phase earth screens are not required.

Both Type 409.1 and Type 410.1 incorporate a vulcanized inner PCP bedding, open-weave polyamide anti-torsion reinforcing braid and an extra-heavy-duty HD-85-PCP polychloroprene outer sheath engineered for surface trailing and drum reeling. TEBAOFLEX manufactures custom 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 409.1 1.1/1.1 kV surface mining cable, showing three Class 5 tinned copper power cores with Class 2 thick-wall R-EP-90 EPR insulation and composite tinned-copper/polyester phase screens, two interstitial earth cores and one pilot core around a central cradle, inner PCP bedding, anti-torsion braid and heavy-duty HD-85-PCP outer sheath.

Applications

Specify AS/NZS 2802 Type 409.1 and Type 410.1 cables for 1.1/1.1 kV open-cut mining, hard-rock metalliferous headings, quarry crushers and heavy surface reeling equipment.

• Open-cut blast-hole drills, mobile auxiliary lighting towers, hydraulic excavators and mobile crushing plants operating on 415 V to 1000 V (1.1/1.1 kV) trailing feeders.
• Underground hard-rock gold, copper, nickel and zinc jumbo drills, loaders and shotcrete rigs requiring Class 2 heavy-wall EPR mechanical protection.
• High-head open-pit mine dewatering pontoon pumps and tailings-dam booster stations exposed to harsh sunlight, mud and rocky benches.
• Port bulk-handling hoppers, mobile ship-loading conveyors and quarry stackers requiring 1.1/1.1 kV reeling cables with earth-continuity pilot lockout.

Related selection resources

• Mining and tunneling cable engineering solutions
• Type 209 and Australian mining cable voltage and screen selection notes
• AS/NZS 2802 Type 409 Class 2 composite screened mining cable (1.1 to 22 kV)
• AS/NZS 1802 Type 210 1.1 kV flexible rubber underground mining cable
• AS/NZS 1972 Type 9 Screened Mining Control and Signalling Cable

Specifications

Compare the 2.2 mm to 2.8 mm Class 2 EPR wall of Type 409.1 and Type 410.1 against the 1.6 mm to 2.4 mm wall of AS/NZS 1802 Type 209 and Type 210 when verifying gland entry diameters.

Current ratings are referenced to 30 C ambient air in single-circuit free-air layout; apply AS/NZS 2802 ambient temperature and drum-layer derating factors where applicable.

Standards

Certifications and document support

TEBAOFLEX company certificates and quality system documentation

Standards New Zealand — AS/NZS 2802 Surface Mining Cable Standard