Overview of AS/NZS 2802 Type 409 Cable

AS/NZS 2802 Type 409 1.1-22 kV is a heavy-duty flexible trailing cable designed for demanding mining, industrial, and mobile equipment applications where excellent flexibility, abrasion resistance, weather resistance, and mechanical durability are essential.

This composite screened cable incorporates three power cores with a central extensible pilot core and is engineered for trailing and most reeling operations in harsh environments such as open-pit mines, underground mining sites, quarry operations, and heavy industrial plants.

The cable is particularly suitable for:

• Mining pumps

• Electric shovels

• Draglines

• Blasthole drills

• Mobile mining equipment

• Reeling systems

• Trailing cable applications

For enhanced mechanical performance, all constructions except Type 409.1 below 50 mm² can incorporate a polyaramid yarn braid reinforcement for exceptional cut-through and tear resistance during severe flexing and mechanical handling.

Standards and Compliance

• AS/NZS 2802 compliant

• Fire retardant construction

• Designed for heavy-duty mining and industrial environments

Key Features of Type 409 Trailing Cable

Excellent Flexibility

The cable is optimized for continuous flexing and repeated trailing operations on mobile equipment.

Composite Screened Design

Each power core incorporates a composite earth screen made from tinned annealed copper wires and polyester yarn to provide reliable grounding and enhanced electrical protection.

Central Extensible Pilot

A centrally positioned pilot core supports monitoring, grounding continuity, and control functions.

Superior Abrasion Resistance

The HD-85-PCP heavy-duty sheath provides excellent resistance to abrasion, impact, and rough mining conditions.

High Tear and Cut-Through Resistance

Optional polyaramid braid reinforcement significantly improves mechanical durability in reeling and dragging operations.

Excellent Environmental Resistance

Suitable for:

• Frequent chemical exposure

• Temporary water immersion

• Severe weather conditions

• High UV and solar radiation exposure

Fire Retardant Performance

Designed to reduce flame propagation in hazardous industrial and mining environments.

Cable Construction

Conductor

• Tinned copper conductor

• Three power cores plus central pilot

• Flexible construction for trailing applications

Conductor Tape

1.1/1.1 kV

• Polyester tape

3.3 kV and Above

• Semiconductive screen

Insulation

• Class 2 EPR insulation (R-EP-90)

• High thermal and mechanical stability

• Excellent flexibility

Insulation Tape

1.1/1.1 kV

• Proofed textile tape

3.3 kV and Above

• Semiconductive screen

Composite Earth Screen

The composite screen consists of:

• Tinned annealed copper wires

• Polyester yarn reinforcement

This design improves:

• Earth continuity

• Mechanical flexibility

• Electrical screening performance

Core Identification

Power core colours:

• Red

• White

• Blue

Pilot Core

• Single extensible pilot core

• Positioned centrally within the cable

Maximum DC Resistance

For power cores up to 35 mm²:

• 3 Ω/100 m

For power cores above 35 mm²:

• 2 Ω/100 m

Outer Sheath

Material

• Heavy-duty HD-85-PCP sheath

Optional Reinforcement

• Polyaramid yarn braid reinforcement

Benefits

• High abrasion resistance

• Excellent tear resistance

• Enhanced cut-through protection

• Long service life under severe mining conditions

Electrical and Environmental Performance

Installation Conditions

Type 409 cables are suitable for:

• Free air installation

• Mobile mining equipment

• Trailing systems

• Reeling operations

• Heavy industrial environments

Class 2 constructions utilize standard insulation and sheath materials while maintaining excellent flexibility and durability for demanding mining applications.

Voltage Ratings Available

AS/NZS 2802 Type 409 cable is available in the following voltage classes:

Typical Mining and Industrial Applications

Open-Pit Mining Equipment

Designed for continuous flexing and mechanical stress on:

• Draglines

• Rope shovels

• Electric excavators

• Mobile crushers

Pump Power Supply

Suitable for:

• Dewatering pumps

• Slurry pumps

• Portable mining pumps

Reeling Systems

Excellent performance for:

• Drum reeling systems

• Mining cable reels

• Mobile stackers and reclaimers

Blasthole Drills

Provides reliable power transmission under:

• Continuous vibration

• Abrasion

• Torsional stress

Advantages of Composite Screened Mining Cables

The composite screened design used in Type 409 offers several advantages:

• Improved earth fault protection

• Enhanced electrical screening

• Better mechanical flexibility compared to conventional copper-only screens

• Reduced cable weight

• Improved durability in trailing applications

Why Choose AS/NZS 2802 Type 409 Cable?

AS/NZS 2802 Type 409 cables are engineered for the severe operating conditions encountered in mining and heavy industrial environments. The combination of flexible tinned copper conductors, EPR insulation, composite screens, and heavy-duty PCP sheath construction ensures reliable long-term performance under continuous flexing, abrasion, impact, moisture, and UV exposure.

Key benefits include:

• High flexibility

• Excellent abrasion resistance

• Heavy-duty mechanical protection

• Reliable trailing and reeling performance

• Fire retardant properties

• Excellent weather resistance

• Suitable for harsh mining environments