AS/NZS 1802 Type 230 and Type 235 Shuttle Car Reeling Cable
Underground coal shuttle car and mobile reeling machine cable engineered to AS/NZS 1802 in Type 230 (three conductive-elastomer screened power cores plus earth core) and Type 235 (three metallic-composite screened power cores plus central or interstitial pilot core) at 1.1/1.1 kV and 1.9/3.3 kV. Reinforced with an anti-torsion braid and extra-heavy-duty HD-85-PCP polychloroprene sheath for high-speed bi-directional shuttle car spooling. MOQ 50 m; lead time 7 to 45 working days.
Underground coal mine shuttle cars, tether-assisted haulage vehicles and mobile breaker-feeders subject reeling cables to rapid bi-directional acceleration, tight sheave reversing, high axial tension and constant ribside abrasion. AS/NZS 1802 specifies Type 230 and Type 235 four-conductor round reeling cables specifically for underground coal shuttle car duty at 1.1/1.1 kV (Type 230.1 / Type 235.1) and 1.9/3.3 kV (Type 230.3 / Type 235.3).
Selecting between Type 230, Type 235 and Type 275 depends on the mine earth-leakage and earth-continuity protection system. Type 230 incorporates three R-EP-90 EPR power cores screened with extruded semi-conducting elastomer layers and laid up with one unscreened earth conductor (3P + 1E), eliminating metallic screen wire breakage under extreme flexing. Type 235 surrounds each of the three power cores with a tinned-copper and polyester composite earth screen that acts as the collective protective earth, while the fourth core serves as an insulated pilot conductor (3P + 1P) for earth-continuity lockout.
Both Type 230 and Type 235 are built around a tight-pitch core lay locked inside an extruded HD-85-PCP inner bedding, an open-weave synthetic anti-torsion reinforcing braid and a vulcanized extra-heavy-duty HD-85-PCP outer sheath that resists corkscrewing under repeated anchor-point over-running. TEBAOFLEX supplies custom shuttle car 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 1802 Type 235.1 1.1/1.1 kV shuttle car reeling cable, showing three Class 5 tinned copper power cores with R-EP-90 EPR insulation and composite tinned-copper/polyester earth screens, one insulated pilot core, inner PCP bedding, open anti-torsion reinforcing braid and heavy-duty black HD-85-PCP outer sheath.
| Component | Material and construction |
|---|---|
| Power Conductors (3 x Class 5 Tinned Copper) | Flexible stranded annealed tinned copper conductors (16 mm2 to 95 mm2) per AS/NZS 1125 Class 5 engineered for high-cycle shuttle car level-wind reeling. |
| R-EP-90 EPR Insulation System | Extruded semi-conducting conductor screen and high-grade R-EP-90 ethylene propylene rubber insulation complying with AS/NZS 3808. |
| Core Screening (Type 230 vs Type 235) | Type 230 uses flexible semi-conducting elastomeric core screens with a dedicated fourth earth conductor; Type 235 uses helically braided tinned-copper/polyester composite earth screens over each power core. |
| Fourth Core (Earth in Type 230 / Pilot in Type 235) | Class 5 tinned copper fourth core functioning as the main protective earth conductor in Type 230 or as the R-EP-90 insulated pilot conductor in Type 235. |
| Elastomeric Cradle & Inner Bedding | Semi-conductive elastomeric central cradle and extruded HD-85-PCP inner sheath maintaining roundness under multi-layer drum tension. |
| Anti-Torsion Reinforcing Braid | Open-weave polyamide braid vulcanized between the inner and outer sheaths to prevent core twist and jacket slippage in guide sheaves. |
| HD-85-PCP Heavy-Duty Outer Sheath | Flame-retardant, oil-resistant and tear-resistant heavy-duty polychloroprene (HD-85-PCP) outer jacket per AS/NZS 3808. |
Applications
Specify AS/NZS 1802 Type 230 and Type 235 cables for dynamic underground coal haulage and mobile face equipment operating on hydraulic tension reels.
- Underground coal shuttle cars hauling coal between continuous miners and feeder-breakers under high-speed bi-directional reeling.
- Mobile feeder-breakers, roof bolters and auxiliary face haulage units operating on 1.1/1.1 kV or 1.9/3.3 kV gate-end box outlets.
- Non-metallic-screened shuttle car circuits (Type 230) where mines eliminate copper screen strand fatigue in severe sheave-bending paths.
- Composite-screened shuttle car circuits (Type 235) where phase-to-earth fault screening and dedicated pilot continuity monitoring are required in a 4-core geometry.
Related selection resources
Specifications
| Parameter | Value |
|---|---|
| Design standard reference | Engineered to AS/NZS 1802, AS/NZS 1125 and AS/NZS 3808 for underground coal mining reeling duty |
| Rated voltage classes | 1.1/1.1 kV (Type 230.1 and Type 235.1) and 1.9/3.3 kV (Type 230.3 and Type 235.3) |
| Type 230 vs Type 235 core layout | Type 230 is 3 conductive-elastomer screened power cores + 1 earth; Type 235 is 3 composite-screened power cores + 1 pilot |
| Operating and short-circuit temperature | 90 C max continuous conductor temperature and 250 C short-circuit temperature (5 s max) |
| Minimum dynamic bending radius | 6 x overall cable diameter for underground coal shuttle car sheave and reel guidance |
| Commercial supply terms | Minimum order quantity 50 m; manufacturing lead time 7 to 45 working days with full routine electrical test certificates |
| Selection boundary vs Type 275 | Select Type 230 or Type 235 for 4-conductor round shuttle car layouts; select Type 275 for conductive-rubber screened 3-power + 1-pilot + 1-earth constructions. |
| Designation & Core Layout | Voltage Rating | Power Core (mm²) | Power Stranding (No./mm) | Earth Core (mm²) | Nominal EPR Wall (mm) | Nominal O.D. (mm) | Approx. Mass (kg/km) | Current Rating at 30 °C (A) | Min. Bend Radius (mm) |
|---|---|---|---|---|---|---|---|---|---|
| Type 230.1 3x16 + 1E | 1.1/1.1 kV | 16 | 126/0.40 | 10 | 1.6 | 33.8 | 1720 | 105 | 205 |
| Type 230.1 3x25 + 1E | 1.1/1.1 kV | 25 | 196/0.40 | 16 | 1.6 | 37.4 | 2240 | 135 | 225 |
| Type 230.1 3x35 + 1E | 1.1/1.1 kV | 35 | 276/0.40 | 16 | 1.6 | 40.2 | 2790 | 165 | 245 |
| Type 230.1 3x50 + 1E | 1.1/1.1 kV | 50 | 396/0.40 | 25 | 1.8 | 45.0 | 3650 | 200 | 270 |
| Type 230.1 3x70 + 1E | 1.1/1.1 kV | 70 | 360/0.50 | 35 | 1.8 | 49.8 | 4720 | 245 | 300 |
| Type 230.1 3x95 + 1E | 1.1/1.1 kV | 95 | 475/0.50 | 50 | 2.0 | 55.4 | 6120 | 295 | 335 |
| Type 230.3 3x25 + 1E | 1.9/3.3 kV | 25 | 196/0.40 | 16 | 3.0 | 43.6 | 2860 | 140 | 265 |
| Type 230.3 3x35 + 1E | 1.9/3.3 kV | 35 | 276/0.40 | 16 | 3.0 | 46.5 | 3440 | 170 | 280 |
| Type 230.3 3x50 + 1E | 1.9/3.3 kV | 50 | 396/0.40 | 25 | 3.0 | 51.2 | 4380 | 205 | 310 |
| Designation & Core Layout | Voltage Rating | Power Core (mm²) | Power Stranding (No./mm) | Fourth Core (mm²) | Nominal EPR Wall (mm) | Nominal O.D. (mm) | Approx. Mass (kg/km) | Current Rating at 30 °C (A) | Min. Bend Radius (mm) |
|---|---|---|---|---|---|---|---|---|---|
| Type 235.1 3x16 + 1P | 1.1/1.1 kV | 16 | 126/0.40 | 6.0 (Pilot) | 1.6 | 35.2 | 1850 | 105 | 215 |
| Type 235.1 3x25 + 1P | 1.1/1.1 kV | 25 | 196/0.40 | 6.0 (Pilot) | 1.6 | 38.8 | 2390 | 135 | 235 |
| Type 235.1 3x35 + 1P | 1.1/1.1 kV | 35 | 276/0.40 | 10 (Pilot) | 1.6 | 41.8 | 2960 | 165 | 255 |
| Type 235.1 3x50 + 1P | 1.1/1.1 kV | 50 | 396/0.40 | 10 (Pilot) | 1.8 | 46.6 | 3840 | 200 | 280 |
| Type 235.1 3x70 + 1P | 1.1/1.1 kV | 70 | 360/0.50 | 16 (Pilot) | 1.8 | 51.4 | 4950 | 245 | 310 |
| Type 235.1 3x95 + 1P | 1.1/1.1 kV | 95 | 475/0.50 | 16 (Pilot) | 2.0 | 57.0 | 6380 | 295 | 345 |
| Type 235.3 3x25 + 1P | 1.9/3.3 kV | 25 | 196/0.40 | 10 (Pilot) | 3.0 | 45.2 | 3020 | 140 | 275 |
| Type 235.3 3x35 + 1P | 1.9/3.3 kV | 35 | 276/0.40 | 10 (Pilot) | 3.0 | 48.2 | 3610 | 170 | 290 |
| Type 235.3 3x50 + 1P | 1.9/3.3 kV | 50 | 396/0.40 | 10 (Pilot) | 3.0 | 52.8 | 4560 | 205 | 320 |
Ampacity values reflect free-air trailing reference at 30 C ambient; apply AS/NZS 1802 multi-layer shuttle car reel derating factors according to the number of energized layers remaining on the spool.
Confirm whether your gate-end box protection relay matches the 3P+1E conductive-elastomer Type 230 circuit or the 3P+1P metallic-composite-screened Type 235 circuit prior to ordering.
Standards
| Standard or specification | Application |
|---|---|
| AS/NZS 1802 | Electric cables — Reeling and trailing — For underground coal mining applications (Type 230 and Type 235). |
| AS/NZS 1125 | Conductors in insulated electric cables and flexible cords (Class 5 tinned annealed copper). |
| AS/NZS 3808 | Insulating and sheathing materials for electric cables (R-EP-90 EPR and HD-85-PCP heavy-duty polychloroprene). |
| AS/NZS 1660.5.6 | Methods of test for electric cables — Fire tests — Vertical flame propagation for individual insulated or sheathed cables. |
Certifications and document support
TEBAOFLEX company certificates and quality system documentation
Standards New Zealand — AS/NZS 1802 Underground Coal Mining Cable Standard
Related cable options
Compare these cable options by service combination, movement, load, voltage and transmission requirement.
TYPE275 1.1 kV Flexible Shuttle Car Mining Cable
A related cable option for a different application or duty profile.
View product
Type 241.1 Mining Cable 1.1 kV | Type 241 Family
A related cable option for a different application or duty profile.
View product
Type 245 Flexible Rubber Mining Cable 1.1–6.6 kV
A related cable option for a different application or duty profile.
View productRequest a cable recommendation and quotation
Send the required services, cable length, mechanical duty, environment, termination and quantity. Our team will review the application before quoting.
- Include the product name or SKU plus the required cable length and quantity.
- Attach a specification, drawing or data sheet when available.