Overview of AS/NZS 2802 Type 440 Cable

AS/NZS 2802 Type 440 1.1–22 kV is a Class 2 composite screened flexible trailing cable designed for demanding mining, tunneling, industrial, and mobile equipment applications where high mechanical strength, excellent flexibility, and long service life are essential.

This cable is specifically engineered for trailing and most reeling applications involving mobile mining machinery, cable reel systems, stackers, reclaimers, shuttle cars, excavators, continuous miners, and heavy-duty portable electrical equipment operating in harsh environments.

Compared with standard trailing cables, Type 440 offers enhanced resistance to abrasion, weathering, mechanical impact, moisture ingress, and chemical exposure. It is particularly suitable for long cable runs where the use of Type 409 or Type 441 could result in pilot resistance values outside required operational limits.

Manufactured in accordance with AS/NZS 2802, the cable combines flexible tinned copper conductors, EPR insulation, composite earth screening, and a heavy-duty PCP sheath to ensure reliable performance under repeated flexing and harsh industrial operating conditions.

Key Features of Type 440 1.1–22 kV Cable

• Manufactured to AS/NZS 2802 standard

• Voltage ratings from 1.1 kV to 22 kV

• Flexible trailing and reeling cable construction

• Composite screened power cores

• Three integrated pilot cores

• Excellent abrasion resistance

• Heavy-duty mechanical impact resistance

• Resistant to chemicals, oils, and industrial contaminants

• Suitable for temporary immersion and wet environments

• UV and weather resistant for outdoor installation

• Flame retardant construction

• EPR insulated flexible power cores

• Heavy-duty HD-85-PCP outer sheath

• Optional polyaramid Kevlar® braid reinforcement

• Designed for mining and mobile equipment applications

Applications

AS/NZS 2802 Type 440 flexible trailing cable is widely used in:

• Underground mining operations

• Open-pit mining equipment

• Continuous miners

• Shuttle cars

• Draglines

• Reeling drum systems

• Stackers and reclaimers

• Mobile crushing plants

• Tunnel boring machines (TBM)

• Conveyor systems

• Heavy-duty industrial mobile equipment

• Quarry operations

• Port and bulk material handling systems

The cable is designed for installation in free air and on mobile equipment where repeated movement, flexing, and mechanical stress are common operating conditions.

Cable Construction

Conductor

Power Conductors

• Flexible stranded tinned copper conductors

• Three power cores

• Excellent flexibility and corrosion resistance

• Optimized for dynamic trailing applications

Pilot Conductors

• Three pilot cores

• Elastomer covered

• Proofed tape protection

• Positioned within cable interstices

Conductor Tape

For 1.1/1.1 kV Versions

• Polyester conductor tape

For 3.3 kV and Above

• Semiconductive conductor screen

The semiconductive layer ensures uniform electrical stress distribution and improved electrical performance in medium-voltage applications.

Insulation

• EPR (R-EP-90) elastomer insulation

• White insulation compound

• Maximum conductor operating temperature: +90°C

• Excellent thermal and electrical stability

• Superior flexibility compared with thermoplastic insulation systems

EPR insulation provides outstanding resistance to:

• Heat

• Moisture

• Flex fatigue

• Electrical stress

• Mechanical deformation

Insulation Screen / Tape

1.1 kV Versions

• Proofed textile tape

3.3 kV and Above

• Semiconductive insulation screen

This construction improves dielectric performance and minimizes the risk of partial discharge in medium-voltage installations.

Composite Earth Screen

The cable incorporates a composite screen consisting of:

• Tinned annealed copper wires

• Polyester yarn reinforcement

The composite screen functions as:

• Earth continuity conductor

• Electrical screen

• Mechanical reinforcement component

Benefits include:

• Improved grounding reliability

• Enhanced fault current capability

• Better flexibility than conventional metallic screening systems

Core Identification

Power core colors:

• Red

• White

• Blue

• Braid tracers

This identification system simplifies installation and maintenance procedures in mining and industrial environments.

Outer Sheath

Sheath Material

• Heavy-duty HD-85-PCP elastomer sheath

Characteristics

• High abrasion resistance

• Excellent weather resistance

• UV resistant

• Oil resistant

• Chemical resistant

• Flexible under dynamic movement

• Resistant to industrial contaminants

Optional Reinforcement

• Polyaramid Kevlar® braid reinforcement

Optional reinforcement significantly improves:

• Tensile strength

• Mechanical durability

• Resistance to cable crushing and pulling forces

Electrical and Mechanical Performance

Flame Retardancy

Type 440 cable features flame-retardant construction suitable for mining and industrial safety requirements.

Operating Temperature

• Maximum operating temperature: +90°C

• Minimum operating temperature: -25°C

The cable remains flexible and operational in both hot mining environments and cold outdoor installations.

Chemical Resistance

Type 440 offers very good resistance to:

• Industrial oils

• Mining chemicals

• Hydraulic fluids

• Grease

• Moisture contamination

Suitable for frequent chemical exposure conditions.

Water Resistance

• Suitable for temporary immersion

• Suitable for wet mining environments

• Reliable under temporary water coverage conditions

UV and Weather Resistance

The PCP outer sheath is suitable for:

• Direct sunlight exposure

• Outdoor mining applications

• Harsh weather conditions

• High UV environments

Voltage Classes Available

AS/NZS 2802 Type 440 cable is available in multiple voltage ratings:

Advantages of Type 440 Cable in Mining Applications

Excellent Flexibility

The finely stranded tinned copper conductors and elastomeric insulation system provide superior flexibility for repeated trailing operations.

Long Service Life

Heavy-duty PCP sheathing and optional aramid reinforcement help reduce:

• Abrasion damage

• Jacket cracking

• Mechanical fatigue

• Premature cable failure

Reliable Pilot Core Performance

The integrated three-pilot-core design helps maintain reliable control and monitoring functions over long cable runs.

This is particularly important in:

• Large mining sites

• Long trailing distances

• High-current mobile equipment systems

Improved Electrical Safety

Composite screening and semiconductive layers improve:

• Electrical stress control

• Earth continuity

• Operational safety

• Fault protection reliability

Installation Conditions

Suitable installation environments include:

• Free air installations

• Mobile mining equipment

• Reeling drum systems

• Trailing cable systems

• Outdoor industrial environments

• Wet and abrasive operating conditions

Typical Mining Equipment Using Type 440 Cable

Common equipment applications include:

• Continuous miners

• Shuttle cars

• Mobile transformers

• Excavators

• Reclaimers

• Stackers

• Tunnel boring machines

• Conveyor transfer systems

• Drilling equipment

• Heavy-duty reeling systems

Why Choose AS/NZS 2802 Type 440 Cable?

Type 440 trailing cable is designed for operations where standard industrial flexible cables cannot survive the combination of:

• Heavy mechanical abuse

• Continuous movement

• Abrasion

• Moisture

• Chemical exposure

• UV exposure

• Dynamic flexing

Its composite screened construction, integrated pilots, heavy-duty PCP sheath, and optional aramid reinforcement make it an ideal solution for demanding mining and industrial power applications.

AS/NZS 2802 Type 440 1.1–22 kV flexible trailing cable is a high-performance mining and industrial cable engineered for severe operating environments requiring excellent flexibility, electrical reliability, and mechanical durability.

With composite screened power cores, EPR insulation, integrated pilot conductors, and heavy-duty PCP sheath construction, Type 440 provides dependable performance for trailing and reeling applications across mining, tunneling, bulk handling, and heavy industrial sectors.

Its resistance to abrasion, chemicals, moisture, UV exposure, and mechanical impact makes it a reliable long-term solution for mobile electrical equipment operating in the world’s harshest environments.

Keywords: AS/NZS 2802 Type 440 cable, Type 440 1.1-22 kV trailing cable, mining trailing cable, flexible reeling cable, composite screened mining cable, EPR insulated mining cable, heavy duty mining cable, mobile equipment cable, AS/NZS mining cable, underground mining cable, Type 440 flexible cable, PCP sheathed trailing cable, medium voltage mining cable, reeling drum cable, mining power cable